Removal

ENGINE ASSEMBLY

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9) (w/ Active Stabilizer System):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

COMPONENTS (Part 15):

COMPONENTS (Part 16):

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM 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.

3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE FRONT WHEELS
5. REMOVE COOL AIR INTAKE DUCT SEAL
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE ENGINE ROOM SIDE COVER LH

8. REMOVE NO. 1 AIR CLEANER INLET
(a) Remove the bolt and No. 1 air cleaner inlet.

9. REMOVE V-BANK COVER
(a) Remove the 2 nuts and V-bank cover.

10. REMOVE ENGINE UNDER COVER
11. REMOVE NO. 2 ENGINE UNDER COVER

12. REMOVE ENGINE UNDER COVER REAR LH
(a) Remove the 2 screws and cover.

13. REMOVE ENGINE UNDER COVER REAR RH
(a) Remove the 2 screws and cover.

14. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER
(a) Remove the 4 bolts and protector.

15. REMOVE ECM COVER
(a) Remove the 3 bolts and ECM cover.

16. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the connector holder.

(b) Using a screwdriver, disconnect the connector holder.

HINT: Tape the screwdriver tip before use.

(c) Disconnect the 5 ECM connectors.
(d) Remove the nut and disconnect the positive battery (+) cable.
(e) Remove the engine room No. 1 relay block cover.
(f) Remove the nut and disconnect the wire from the engine room No. 1 junction block.

(g) Remove the bolt and disconnect the ground cable.

(h) Remove the 2 bolts and ground cable.

(i) Remove the bolt and ground cable.

17. REMOVE POWER STEERING LINK WIRE HARNESS
(a) Remove bolt (A) to disconnect the ground wire from the bracket.
(b) Remove the 2 clamps to disconnect the wire harness from the bracket.
(c) Disconnect 2 connectors (C) and (D) from the power steering link assembly.
(d) Release the lock of connector (E) and disconnect connector (E) from the power steering link assembly.
(e) Remove bolt (B) and the power steering ground wire from the power steering link assembly.

18. DRAIN ENGINE OIL
19. DRAIN ENGINE COOLANT
20. DRAIN AUTOMATIC TRANSMISSION FLUID
21. REMOVE INTAKE AIR CONNECTOR PIPE

22. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connect and clamp.
(b) Remove the 3 bolts and air cleaner assembly.

23. DISCONNECT RADIATOR HOSE INLET
24. DISCONNECT RADIATOR HOSE OUTLET
25. DISCONNECT NO. 1 OIL COOLER INLET TUBE
26. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE
27. REMOVE RADIATOR ASSEMBLY
(a) Removal procedure.

28. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Remove the No. 2 fuel pipe clamp.

(b) Disconnect the fuel tube connector connected to the fuel main tube, then pinch and pull the connector.

29. REMOVE FAN AND GENERATOR V-BELT

30. DISCONNECT HEATER WATER INLET HOSE A
(a) Remove the clamp and disconnect the heater water inlet hose A.

31. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
(a) Remove the clamp and disconnect the heater water outlet hose A.

32. DISCONNECT UNION TO CHECK VALVE HOSE
(a) Remove the clamp and disconnect the union to check valve hose.

33. DISCONNECT COOLER COMPRESSOR ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 bolts, nut and bracket.
(c) Remove the compressor.

34. REMOVE FRONT CONSOLE UPPER PANEL GARNISH
35. REMOVE CONSOLE UPPER PANEL ASSEMBLY
36. REMOVE INSTRUMENT PANEL FINISH PANEL END RH
37. REMOVE INSTRUMENT PANEL FINISH PANEL END LH
38. DISCONNECT HEATED OXYGEN SENSOR CONNECTOR
(a) Disconnect the 2 oxygen sensor connectors.
(b) Disconnect the grommet and pass the sensor connector out of the cabin through the floor panel.

39. REMOVE REAR NO. 1 FLOOR PANEL BRACE

40. REMOVE FRONT FLOOR BRACE CENTER
(a) Remove the 4 bolts and front floor brace center.

41. REMOVE FRONT EXHAUST PIPE ASSEMBLY
42. REMOVE FRONT NO. 5 FLOOR HEAT INSULATOR
43. REMOVE FRONT NO. 6 FLOOR HEAT INSULATOR
44. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR
(a) Remove the 4 nuts and heat insulator.

45. REMOVE AIR GUIDE PLATE OUTSIDE RH
46. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
47. REMOVE FRONT TWC

(a) Remove the 6 nuts and 2 TWCs.

(b) Remove the 2 gaskets from the 2 TWCs.

48. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
(a) Remove the 2 bolts and support bracket.

49. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET

50. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
(a) Remove the nut and disconnect the shifting rod.

51. DISCONNECT HEIGHT CONTROL SENSOR LINK
(a) Remove the nut and disconnect the height control sensor link.

52. DISCONNECT SHOCK ABSORBER ASSEMBLY FRONT LH
(a) Support the front suspension lower arm with a jack.

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

(b) Loosen the bolt while holding the nut. Disconnect the lower part of the front shock absorber from the front suspension lower arm.

NOTICE: Do not remove the nut.

53. DISCONNECT SHOCK ABSORBER ASSEMBLY FRONT RH
(a) Support the front suspension lower arm with a jack.

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

(b) 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.

54. DISCONNECT LOWER BALL JOINT ASSEMBLY FRONT LH
(a) Remove the 2 bolts and steering knuckle from the lower ball joint.

55. DISCONNECT LOWER BALL JOINT ASSEMBLY FRONT RH
(a) Remove the 2 bolts and disconnect the steering knuckle from the lower ball joint.

56. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) 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.

(b) Loosen bolt (A) and remove bolt (B), then slide the No. 2 steering intermediate shaft.

HINT:
^ Do not remove bolt (A).
^ Do not disconnect the No. 2 steering intermediate shaft from the power steering link.

(c) Put matchmarks on the No. 2 steering intermediate shaft and the power steering link.
(d) Separate the No. 2 intermediate shaft from the power steering link.

57. REMOVE FRONT ACTIVE STABILIZER CONTROL ACTUATOR ASSEMBLY (w/Active Stabilizer System)
(a) Remove the front active stabilizer control actuator assembly.

58. REMOVE ENGINE WITH TRANSMISSION ASSEMBLY
(a) Set the engine lifter.

(b) Remove the bolt and disconnect the earth wire.

(d) Remove the 10 bolts and 2 nuts shown in the illustration.
(e) Operate the engine lifter, then remove the from the vehicle.

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

59. REMOVE ENGINE WIRE
60. REMOVE NO. 1 OIL COOLER INLET TUBE
(a) Remove the 2 bolts and clamps.

(b) Loosen the union nut and remove the oil cooler inlet tube.

61. REMOVE NO. 1 OIL COOLER OUTLET TUBE
(a) Loosen the union nut and remove the oil cooler outlet tube.

62. DISCONNECT WIRE HARNESS AND CONNECTORS

(a) Tilt down the automatic transmission.

NOTICE: Take care so that the cooling fan does not come into contact with the fan shroud.

(b) Remove the 5 bolts and wire harness clamps.

HINT: Bolt (A) is tightened to the transmission housing.

(c) Disconnect the park/neutral position switch connector.
(d) Disconnect the transmission wire connector.
(e) Disconnect the 2 speed sensor connectors.
(f) Disconnect the wire harness from the automatic transmission.

63. REMOVE FLYWHEEL HOUSING UNDER COVER
(a) Remove the 2 bolts and under cover.

64. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

(a) Turn the crankshaft to gain access to each bolt.
(b) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.

65. REMOVE DRIVE PLATE & RING GEAR SUBASSEMBLY
(a) Remove the 8 bolts, rear spacer, ring gear and front spacer.

66. REMOVE OIL DIPSTICK GAUGE GUIDE
(a) Remove the bolt, dipstick and O-ring.

67. REMOVE FRONT ENGINE MOUNTING INSULATOR
(a) Remove the 2 bolts, then remove the front suspension crossmember sub-assembly from the engine.

68. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 4 bolts and heat insulator.

69. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Remove the 8 nuts, exhaust manifold and gasket.

70. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If the warpage is greater than the maximum, replace the manifold.

71. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 4 bolts and heat insulator.

72. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Remove the 8 nuts, exhaust manifold and gasket.

73. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If the warpage is greater than the maximum, replace the manifold.

74. REMOVE NO. 2 WIRING HARNESS HEAT INSULATOR
(a) Remove the 2 bolts and No. 2 wiring harness heat insulator.

75. REMOVE ENGINE STAND
76. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Remove the manifold.

77. REMOVE NO. 1 IDLER PULLEY BRACKET SUBASSEMBLY
78. REMOVE GENERATOR ASSEMBLY

LH Bank:

79. REMOVE NO. 1 ENGINE HANGER
(a) Remove the 2 bolts and engine hanger.

RH Bank:

80. REMOVE NO. 2 ENGINE HANGER
(a) Remove the 2 bolts and engine hanger.

81. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY RH
(a) Remove the cap nut, 3 bolts, timing belt cover and gasket.

82. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY LH
(a) Remove the cap nut and disconnect the No. 3 water by-pass pipe from the timing belt cover.
(b) Disconnect the 2 water by-pass hoses from the No. 3 water by-pass pipe.
(c) Disconnect the engine wire from the 2 wire clamps.
(d) Disconnect the camshaft position sensor connector.
(e) Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
(f) Remove the wire grommet from the timing belt cover.
(g) Remove the 4 bolts.
(h) Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
(i) Disconnect the wire clamp for the sensor from the timing belt cover.
(j) Remove the connector holder from the sensor connector.
(k) Remove the timing belt cover.

83. REMOVE WATER INLET HOUSING
(a) Remove the 2 bolts and inlet housing.

84. REMOVE FRONT WATER BY-PASS JOINT
(a) Disconnect the ECT sensor connector.
(b) Remove the 4 nuts, water by-pass joint and 2 gaskets.

COMPONENTS (Part 13):

85. REMOVE REAR WATER BY-PASS JOINT
(a) Disconnect the heater inlet hose from the water bypass joint.
(b) Remove the 4 nuts, water by-pass joint and 2 gaskets.

86. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Disconnect the heater outlet hose from the water by-pass pipe.
(b) Disconnect the wire clamp (for knock sensor 1, 2) from the bracket of the water by-pass pipe.
(c) Remove the bolt.
(d) Pull out the water by-pass pipe from the water pump.
(e) Remove the O-ring from the water by-pass pipe.

87. REMOVE STARTER ASSEMBLY
88. REMOVE OIL FILLER CAP HOUSING
(a) Remove the 2 nuts and housing.

89. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Disconnect the 2 sensor connectors.
(b) Remove the 2 bolts and 2 oil control valves.

90. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.

91. REMOVE VVT SENSOR
(a) Disconnect the 2 sensor connectors.
(b) Remove the 2 bolts and sensors.

92. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.

93. REMOVE KNOCK SENSOR
(a) Disconnect the 2 sensor connectors.
(b) Remove the 2 sensors.

94. REMOVE IGNITION COIL
(a) Remove the 8 bolts and 8 ignition coils.

95. REMOVE OIL PRESSURE SWITCH
(a) Disconnect the oil pressure switch connector.

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

96. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
(a) Disconnect the oil pressure switch connector.
(b) Remove the stud bolt, 2 nuts and oil filter bracket with gasket.

97. REMOVE ENGINE OIL LEVEL SENSOR
(a) Disconnect the sensor connector.
(b) Remove the 4 bolts, sensor and gasket.

98. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT RH
(a) Remove the 4 bolts and mounting bracket.

99. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a) Remove the 4 bolts and mounting bracket.