Engine Assembly, Removal

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
a. Discharge fuel system pressure.
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
6. REMOVE FRONT FENDER APRON SEAL LH
7. REMOVE FRONT FENDER APRON SEAL RH
8. DRAIN ENGINE OIL
9. DRAIN ENGINE COOLANT
10. DRAIN AUTOMATIC TRANSAXLE FLUID
11. DRAIN TRANSFER OIL (for 4WD)
12. REMOVE FR WIPER ARM LH
13. REMOVE FR WIPER ARM RH
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
15. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
16. REMOVE COWL PANEL SUB-ASSEMBLY
17. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER

18. REMOVE V-BANK COVER SUB-ASSEMBLY
a. Using a 5 mm hexagon wrench, remove the 3 nuts.
b. Disconnect the 2 clips, and remove the cover.
19. REMOVE BATTERY
20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
22. REMOVE AIR CLEANER CASE
23. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
24. REMOVE VANE PUMP V BELT
25. REMOVE GENERATOR ASSEMBLY
26. REMOVE GENERATOR BRACKET NO. 2

27. REMOVE GENERATOR BELT ADJUSTING BAR
a. Remove the 2 bolts, 2 nuts and adjusting bar.

28. REMOVE ENGINE MOVING CONTROL ROD
a. Remove the 4 bolts and control rod.

29. REMOVE ENGINE MOUNTING STAY NO. 2 RH
a. Remove the bolt, mounting stay No. 2 RH and mounting bracket No. 2 RH.

30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the bolt, nut and adjusting bar bracket.
b. Remove the 3 bolts and disconnect the compressor.

HINT: Hang up the hoses instead of detaching.

31. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
32. DISCONNECT UNION TO CHECK VALVE HOSE
a. Remove the vacuum hose for the brake booster.

33. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
a. Remove the fuel pipe clamp.

b. Disconnect the connector from the tube while pinching part A with fingers as shown in the illustration.

NOTICE:
^ Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
^ Disconnect the connector with your hands.
^ Do not bend, fold or rotate the nylon tube.
^ If the pipe and connector are stuck together, push and pull the connector until it comes free.
^ Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

34. DISCONNECT HEATER INLET WATER HOSE
35. DISCONNECT HEATER OUTLET WATER HOSE
36. DISCONNECT RADIATOR HOSE INLET
37. DISCONNECT RADIATOR HOSE OUTLET
38. DISCONNECT OIL COOLER INLET TUBE NO. 1
39. DISCONNECT OIL COOLER OUTLET TUBE NO. 1

40. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO. 1
a. Disconnect the oil reservoir to pump hose No. 1.

41. DISCONNECT STEERING GEAR OUTLET RETURN TUBE
a. Disconnect the steering gear outlet return tube.
42. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

43. SEPARATE ENGINE WIRE
a. Disconnect the engine wire from the ECM and junction block.
b. Disconnect the engine wire from the engine room junction block.
(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, release the engine room junction block. Disconnect the engine wire by pulling it upward.
c. Remove the 2 nuts and pull out the engine wire.
d. Remove the body ground.
44. REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD)
45. DISCONNECT EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
46. DISCONNECT EXHAUST PIPE ASSEMBLY FRONT
47. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
48. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
a. Using a 6 mm socket hexagon wrench, hold the ball stud.
b. Remove the nut and disconnect the stabilizer link.
49. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

50. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, strike the lock nut covering to remove it.
SST 09930-00010

NOTICE:
^ Set the drive shaft's groove so that it faces up. Then use the SST and hammer.
^ Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged.
^ Do not sharpen the tip of the SST.

b. Using a 30 mm socket wrench, remove the lock nut.
51. REMOVE FRONT AXLE HUB RH NUT

HINT: Use the same procedures described for the LH side.

52. DISCONNECT SPEED SENSOR FRONT LH
a. Remove the bolt and disconnect the speed sensor from the steering knuckle.

NOTICE: Keep the speed sensor tip and connection free from foreign matter.

53. DISCONNECT SPEED SENSOR FRONT RH

HINT: Use the same procedures described for the LH side.

54. SEPARATE TIE ROD END SUB-ASSEMBLY LH
a. Remove the cotter pin and nut.
b. Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011

NOTICE: Do not damage the dust cover of the ball joint.

55. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

56. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
a. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
b. Using a plastic hammer, disconnect the drive shaft from the axle hub.
57. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Use the same procedures described for the LH side.

58. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. Remove the 2 bolts and flywheel housing under cover.

c. Remove the 6 torque converter setting bolts.

59. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
a. Loosen the sliding yoke bolt.

b. Place matchmarks on the steering intermediate shaft and control valve shaft.
c. Remove the bolt and disconnect the steering intermediate shaft.
d. To prevent the steering wheel from rotating, fix the wheel with the seat belt.

NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged.

60. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 6 bolts, 2 nuts, and frame side rail plate sub-assembly LH and RH.

c. Remove the 6 bolts, 2 nuts, and front suspension member brace rear LH and RH
d. Carefully, remove the engine assembly from the vehicle.

e. Install the engine hanger as shown in the illustration.

Part No.:

Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
f. Using a chain block and an engine sling device, hang the engine assembly.

61. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Disconnect the A/F sensor connector.
b. Remove the 3 bolts and insulator.

c. Uniformly loosen and remove the 6 nuts in the sequence shown in the illustration.
d. Remove the manifold and gasket.

62. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 inch)
If the warpage is greater than the maximum, replace the manifold.

63. REMOVE VANE PUMP ASSEMBLY
a. Remove the power steering oil pressure sensor harness.
b. Remove the pressure feed tube clamp.
c. Remove the 2 bolts and vane pump.
64. REMOVE STABILIZER BAR FRONT
a. Remove the stabilizer bar front.
65. REMOVE POWER STEERING LINK ASSEMBLY
a. Remove the power steering link assembly.

66. REMOVE FRONT FRAME ASSEMBLY
a. Remove the 2 nuts and disconnect the engine mounting insulator RH and LH.

b. Remove the nut and disconnect the engine mounting insulator FR.

c. Remove the 2 bolts and disconnect the engine mounting insulator RR.
67. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
68. TEST FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
69. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
70. REMOVE STARTER ASSEMBLY
71. REMOVE ENGINE MOUNTING BRACKET FR
72. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
a. Remove the automatic transaxle assembly.
73. REMOVE TRANSFER STIFFENER PLATE RH (for 4WD)
74. REMOVE AUTOMATIC TRANSAXLE W/TRANSFER (for 4WD)
a. Remove the automatic transaxle assembly.
75. REMOVE ENGINE MOUNTING BRACKET RR
76. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
77. INSTALL ENGINE STAND
78. REMOVE ENGINE HANGER NO. 2

79. REMOVE EMISSION CONTROL VALVE SET
a. Disconnect the 2 VSV connectors [A].
b. Remove the wire harness clamp [B].

c. Disconnect the fuel vapor feed hose No. 1 [C].
d. Disconnect the fuel vapor feed hose No. 2 [D].
e. Disconnect the 2 vacuum hoses [E].
f. Remove the clamp [F].
g. Remove the 2 nuts and the emission control valve set.

80. REMOVE INTAKE AIR SURGE TANK
a. Disconnect the throttle motor connector [A].
b. Disconnect the water bypass hose No. 3 [B].
c. Disconnect the water bypass hose No. 2 [C].
d. Disconnect the union to check valve hose [D].

e. Disconnect the ventilation hose [E].

f. Remove the 3 nuts and disconnect the pressure feed tube [F].

g. Remove the 2 bolts and engine hanger No. 1 [G].
h. Remove the 2 bolts and surge tank stay No. 1 [H].
i. Remove the 2 bolts and surge tank stay No. 2 [I].

j. Using a socket hexagon wrench 8, remove the 4 bolts.
k. Remove the 2 nuts, emission control valve bracket and intake air surge tank.
l. Remove the gasket from the intake air surge tank.

81. INSPECT INTAKE AIR SURGE TANK
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.10 mm (0.0039 inch)
If the warpage is greater than the maximum, replace the manifold.

82. REMOVE INTAKE MANIFOLD
a. Remove the nut and disconnect the ground cable [A].
b. Disconnect the 6 fuel injector connectors [B].

c. Uniformly loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.

83. INSPECT INTAKE MANIFOLD
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and intake air surge tank for warpage.

Maximum Warpage:

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

84. REMOVE WATER OUTLET
a. Disconnect the radiator hose inlet.
b. Disconnect the engine coolant temperature sensor connector [B].
c. Remove the clamp [C].
d. Remove the 2 bolts, 2 nuts and 2 washers.
e. Lock the hose clamp [E] as shown in the illustration and remove the water outlet together with the water bypass hose No. 1.
f. Remove the 2 gaskets from the 2 cylinder heads.
85. REMOVE IGNITION COIL ASSEMBLY

86. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
a. Disconnect the A/F sensor connector.
b. Remove the bolt, nut and insulator No. 3.

c. Remove the 2 bolts and insulator No. 2.

d. Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration.
e. Remove the converter and gasket.

f. Remove the 2 bolts and manifold stay.

87. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 inch)
If the warpage is greater than the maximum, replace the manifold.
88. REMOVE ENGINE MOUNTING BRACKET RH

89. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
90. REMOVE GENERATOR BRACKET NO. 1
91. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
92. REMOVE WATER INLET PIPE
93. REMOVE WATER INLET
94. REMOVE THERMOSTAT

95. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Remove the oil pressure switch.
96. REMOVE KNOCK SENSOR
a. Remove the 2 nuts and 2 sensors.
97. REMOVE PARTIAL ENGINE ASSEMBLY