Removal
ENGINE ASSEMBLYCOMPONENTS (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):
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected.
3. DRAIN ENGINE COOLANT
4. DRAIN AUTOMATIC TRANSMISSION FLUID
5. DRAIN ENGINE OIL
6. DISCONNECT HOOD SUPPORT ASSEMBLY
7. REMOVE HOOD SUB-ASSEMBLY
(a) Remove the 4 bolts and hood.
8. REMOVE FRONT WIPER MOTOR AND LINK
(a) Remove the front wiper motor and link.
9. REMOVE FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY
10. REMOVE V-BANK COVER
11. REMOVE NO. 2 AIR CLEANER HOSE
12. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT
13. REMOVE NO. 1 ENGINE UNDER COVER
14. REMOVE INTAKE AIR SURGE TANK
15. DISCONNECT ENGINE WIRE
(a) Engine Room RH Side:
(1) Disconnect the ECM connector labeled A as shown in the illustration.
(2) Remove the junction block cover.
(3) Disconnect the 7 connectors from junction block labeled B shown in the illustration.
(4) Using a clip remover, detach the 2 wire harness clamps labeled B shown in the illustration.
(5) Remove the 2 bolts and ground cable labeled C shown in the illustration.
(6) Disconnect the 2 air pump connectors labeled D shown in the illustration.
(7) Using a clip remover, detach the 2 wire harness clamps labeled E shown in the illustration.
(8) Remove the bolt and bracket labeled F shown in the illustration.
(b) Engine Room LH Side:
(1) Disconnect the 4 connectors from the air injection control driver labeled A shown in the illustration.
(2) Remove the engine room relay block cover.
(3) Disconnect the 2 connectors from the engine room junction block labeled B shown in the illustration.
(4) Remove the nut from the engine room junction block, and disconnect the No. 2 engine wire's cover labeled C shown in the illustration.
(5) Remove the nut and disconnect the wire harness bracket from the inner body panel side labeled D shown in the illustration.
(6) Disconnect the connector, and using a clip remover, detach the front ABS junction connector's clamp from the engine room relay block side labeled E shown in the illustration.
(7) Disconnect the connector from the crankshaft position sensor labeled F shown in the illustration.
(8) Using a clip remover, detach the wire harness clamp from the front engine mounting bracket LH labeled F shown in the illustration.
(9) Remove the bolt and ground cable labeled G shown in the illustration.
(10) Pull out the battery positive cable cover, and then remove the nut and battery positive cable labeled H shown in the illustration.
16. REMOVE NO. 5 AIR INJECTION SYSTEM HOSE
17. REMOVE NO. 4 AIR INJECTION SYSTEM HOSE
18. REMOVE NO. 1 AIR TUBE
19. DISCONNECT NO. 2 AIR TUBE
20. REMOVE AIR SWITCHING VALVE ASSEMBLY
21. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for Regular Cab Standard Deck)
22. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck)
23. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)
24. REMOVE FRONT EXHAUST PIPE ASSEMBLY
25. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
26. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
27. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
28. DISCONNECT RADIATOR HOSE INLET
29. DISCONNECT RADIATOR HOSE OUTLET
30. REMOVE FAN SHROUD
31. REMOVE RADIATOR SIDE DEFLECTOR RH
32. REMOVE RADIATOR SIDE DEFLECTOR LH
33. REMOVE RADIATOR ASSEMBLY
34. DISCONNECT HEATER WATER HOSE
(a) Remove the wire harness clamp.
(b) Disconnect the heater water inlet and outlet hose.
(c) Remove the nut and heater water pipe bracket.
35. DISCONNECT VANE PUMP ASSEMBLY
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the 2 bolts, and disconnect the vane pump.
NOTICE: Do not hit other parts with the pulley when separating the vane pump.
HINT: Make sure to suspend the vane pump securely.
36. REMOVE GENERATOR ASSEMBLY
37. DISCONNECT COOLER COMPRESSOR
(a) Remove the 2 nuts, 2 bolts and disconnect the cooler compressor.
38. DISCONNECT NO. 1 AND NO. 2 FUEL PIPE
(a) Disconnect the No. 1 and No. 2 fuel pipe.
(1) Remove the fuel pipe clamp from the fuel tube connector.
HINT: Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.
(2) Pinch the connector and disconnect the connector and pipe.
HINT: If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(3) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(4) To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
39. REMOVE BATTERY
40. REMOVE FRONT FENDER APRON SEAL LH
41. REMOVE FRONT FENDER APRON SEAL RH
42. REMOVE STARTER ASSEMBLY
(a) Remove the starter (for 1.6 kW Type).
(b) Remove the starter (for 2.0 kW Type).
43. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
(a) Remove the flywheel housing side cover.
(b) Turn the crankshaft to gain access to the 6 bolts and remove the 6 bolts while holding the crankshaft pulley set bolt with a wrench.
44. REMOVE FLYWHEEL HOUSING UNDER COVER
(a) Remove the flywheel housing under cover.
45. REMOVE PROPELLER SHAFT ASSEMBLY (for 2 Joint Type)
46. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type)
47. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
48. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY
49. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
(a) Remove the 4 bolts of the rear No. 1 engine mounting insulator.
(b) Remove the 4 nuts, 4 washers, 4 bolts and No. 3 frame crossmember.
50. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Remove the 4 bolts and engine mounting insulator.
51. DISCONNECT WIRE HARNESS AND CONNECTOR
52. DISCONNECT NO. 1 WATER BY-PASS PIPE
53. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
54. REMOVE ENGINE ASSEMBLY
(a) Install the 2 engine hangers with the 4 bolts shown in the illustration.
Part No.:
Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
(b) Attach the engine sling device and hang the engine with the chain block.
(c) Remove the 2 nuts and 4 bolts from the front engine mounting insulator LH and RH.
(d) Lift the engine out of the vehicle carefully.
NOTICE: Make sure the engine is clear of all wiring and hoses.
(e) Remove the front engine mounting insulator LH and RH.
(f) Place the engine onto a working bench.
55. REMOVE DRIVE PLATE AND RING GEAR
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Remove the 8 bolts, rear spacer, drive plate and front spacer.
56. INSTALL ENGINE STAND
(a) Install the engine onto an engine stand with the bolts.
57. REMOVE ENGINE HANGER
(a) Remove the 4 bolts and 2 engine hangers.