Part 2

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL (STEPS 42-83)

42. DISCONNECT POWER STEERING LINK WIRE HARNESS
a. Remove the bolt (A) to disconnect the earth wire from the bracket.
b. Remove the 2 clamps to disconnect the wire harness from the bracket.
c. Disconnect the 2 connectors (C) and (D) from the power steering link assembly
d. Release the lock of connector (E) and disconnect the connector from the power steering link assembly.
e. Remove the bolt (B) and the power steering earth wire from the power steering link assembly
43. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
44. REMOVE ENGINE AND TRANSMISSION ASSEMBLY
a. Set the engine lifter.

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

c. Remove the 12 bolts shown in the illustration.
d. Operate the engine lifter, then slowly remove the engine from the vehicle.

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

45. INSTALL ENGINE HANGERS
a. Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts as shown in the illustration.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)

Part No.:

b. Attach an engine sling device and hang the engine with a chain block.
46. REMOVE STARTER ASSEMBLY
47. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
48. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY

a. Remove the oil level gauge.
b. Remove the bolt, then remove the No. 2 oil dipstick guide.
c. Remove the O-ring from the No. 2 oil dipstick guide.

d. Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.
e. Remove the O-ring from the No. 1 oil dipstick guide.
49. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Disconnect the heated oxygen sensor connector.

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

50. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage: 0.7 mm (0.028 inch)

HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 inch). If the warpage is greater than the maximum, replace the manifold.

51. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Disconnect the heated oxygen sensor connector.

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

52. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage: 0.7 mm (0.028 inch)

HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 inch). If the warpage is greater than the maximum, replace the manifold.

53. REMOVE DRIVE PLATE AND RING GEAR SUB ASSEMBLY

a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021

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

54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
a. Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.
55. FIX ENGINE ON ENGINE STAND
a. Fix the engine onto a engine stand with the bolts.
56. REMOVE V-RIBBED BELT

57. REMOVE NO. 2 ENGINE COVER
a. Remove the 3 clips and clamp, then remove the No. 2 engine cover.

58. REMOVE NO. 1 ENGINE COVER
a. Remove the 3 clips, then remove the No. 1 engine cover.

59. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Remove the bolt, plate and idler pulley.
60. REMOVE GENERATOR ASSEMBLY
61. REMOVE COOLER COMPRESSOR ASSEMBLY

62. REMOVE ENGINE MOUNTING BRACKET LH
a. Disconnect the 2 clamps.
b. Remove the 4 bolts and mounting bracket.

63. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and mounting bracket.

64. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.
65. REMOVE WATER PUMP PULLEY
66. REMOVE ENGINE WIRE
a. Remove the engine wire from the engine.

67. REMOVE INJECTOR DRIVER
a. Remove the bolt, 2 nuts and injector driver.
68. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

69. INSPECT INTAKE AIR SURGE TANK ASSEMBLY
a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage: 2.5 mm (0.098 inch)
If the warpage is greater than the maximum, replace the surge tank.
70. REMOVE NO. 2 SURGE TANK STAY
a. Remove the bolt and No. 2 surge tank stay.

71. REMOVE WATER HOSE JOINT
a. Remove the bolt, and disconnect 2 hoses and water hose joint.
72. REMOVE INTAKE MANIFOLD

73. INSPECT INTAKE MANIFOLD
a. Surge tank side:
1. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage: 0.1 mm (0.003 inch)
If the warpage is greater than the maximum, replace the intake manifold.
b. Cylinder head side:
1. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage: 0.1 mm (0.003 inch)
If the warpage is greater than the maximum, replace the intake manifold.

74. REMOVE FUEL TUBE SUB-ASSEMBLY
a. Remove the 2 bolts and fuel tube sub-assembly.
75. REMOVE FUEL PUMP
76. REMOVE FUEL INJECTOR ASSEMBLY
77. REMOVE KNOCK SENSOR

78. REMOVE RADIO SETTING CONDENSER
a. Remove the 2 bolts and 2 radio setting condensers.

79. REMOVE V-BANK COVER BRACKET SUB ASSEMBLY
a. Remove the bolt and V-bank cover bracket.
80. REMOVE IGNITION COIL ASSEMBLY
a. Remove the 6 bolts and 6 ignition coils.

81. REMOVE ENGINE OIL LEVEL SENSOR
a. Remove the 4 bolts, then remove the oil level sensor and gasket.

82. REMOVE OIL PRESSURE SWITCH ASSEMBLY
a. Using a 24 mm deep socket wrench, remove the oil pressure switch.

83. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, remove the temperature sensor.