Removal

REMOVAL

1. REMOVE ENGINE ROOM SIDE COVER

2. REMOVE ENGINE ROOM SIDE COVER LH

3. REMOVE COOL AIR INTAKE DUCT SEAL

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Testing and Inspection

5. REMOVE V-BANK COVER SUB-ASSEMBLY

6. REMOVE NO. 1 ENGINE UNDER COVER

7. REMOVE NO. 2 ENGINE UNDER COVER

8. DRAIN ENGINE COOLANT

9. REMOVE NO. 2 ENGINE MOUNTING STAY RH

10. REMOVE ENGINE MOVING CONTROL ROD BRACKET

11. REMOVE ENGINE MOVING CONTROL ROD

12. REMOVE V-RIBBED BELT

13. DISCONNECT FRONT ENGINE MOUNTING INSULATOR





(a) Remove the 2 hole plugs.
(b) Remove the 3 nuts.

14. DISCONNECT ENGINE MOUNTING INSULATOR RH





(a) Remove the 2 hole plugs.
(b) Remove the 3 nuts.

15. DISCONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY





(a) Remove the 2 hole plugs.
(b) Remove the 2 nuts.

16. REMOVE NO. 2 ENGINE MOUNTING STAY RH

17. DISCONNECT NO. 2 RADIATOR HOSE

18. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH





(a) Remove the 4 bolts
(b) Using SST, loosen the bolt (A).

SST: 09249-37010

(c) Using SST, loosen the bolt (B).

SST: 09961-00950






(d) Place a wooden block between a jack and the engine.

NOTICE:

Make sure to set a jack as shown in the illustration. Do not place the jack on the oil pan.







(e) Jack up the engine slightly, and remove the 2 bolts and No. 1 front engine mounting bracket LH.

NOTICE:

Do not jack up the engine excessively.

HINT:

Lift the engine so that bolt A passes above the No. 1 cooler refrigerant suction pipe.


(f) Lower the engine, and remove the jack.

NOTICE:

When lowering the jack, align the stud bolts of the engine mounting insulators with the bolt holes of the front frame assembly.

19. REMOVE WATER INLET HOUSING





(a) Disconnect the water hose.
(b) Remove the 2 bolts, nut and water inlet housing.






(c) Remove the water inlet housing gasket and water outlet pipe O-ring.


20. REMOVE V-RIBBED BELT TENSIONER PULLEY

(a) Remove the 5 mm bi-hexagon wrench.






(b) Using SST, remove the bolt, dust shield and Vribbed belt tensioner pulley.

SST: 09961-00950

NOTICE:

Do not turn the bolt labeled "L" counterclockwise. Store the V-ribbed belt tensioner pulley so that the bearing does not get damaged.


21. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY







(a) Remove the bolt, No. 2 idler pulley cover plate, No. 2 idler pulley sub-assembly and idler pulley cover plate.

HINT:

Plate diameter:

Idler pulley cover plate: 33.6 mm (1.32 in.)

No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)


22. SEPARATE WATER PUMP PULLEY





(a) Using SST, hold the water pump pulley.

SST: 09960-10010

SST: 09962-01000

SST: 09963-00700


(b) Using SST and a union nut wrench, remove the 4 bolts and separate the water pump pulley from the water pump.

SST: 09961-00950

HINT:

There is not enough clearance to completely remove the water pump pulley from the water pump shaft. Remove the water pump pulley together with the water pump.

23. REMOVE WATER PUMP ASSEMBLY






(a) Remove the 16 bolts, water pump assembly, water pump pulley and water pump gasket.