Engine Removal

Special Tools Required
Engine tilt hanger set (  07KAK-SJ40101)
 

NOTE:


1.Secure the hood in the wide open position (support rod in the lower hole).

2.Relieve fuel pressure:


3.Make sure you have the anti-theft code for the radio, and the navigation system, then write down the customer's radio station presets.

4.Disconnect the negative cable from the battery first, then disconnect the positive cable.

5.Remove the battery.

6.Remove the intake manifold cover.

 

7.Disconnect the intake air temperature (IAT) sensor connector (A), and remove the breather hose (B) and intake air bypass control thermal valve tube (C), then remove the air cleaner housing (D).

 

8.Remove the intake air duct.

 

9.Remove the battery cables (A) from the under-hood fuse/relay box, then remove the harness clamps (B).

 

10.Disconnect the subfuse/relay box connector (C).

11.Remove the ground cable (A).

 

12.Disconnect the engine control module (ECM)/powertrain control module (PCM) connectors (A) and main wire harness connectors (B).

LHD models: 

RHD models: 

13.Disconnect the accelerator pedal position (APP) sensor connector (A).

LHD models: 

RHD models: 

14.Remove the harness clamps (B) and grommet (C), then pull the engine wire harness through the bulkhead.

15.Disconnect the fuel feed hose:


16.Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).

 

17.Remove the clutch slave cylinder and clutch line bracket (M/T).

18.Remove the shift cable and select cable (M/T).

19.Remove the drive belt.

20.Remove the power steering (P/S) pump without disconnecting the P/S hoses.

 

21.Remove the radiator cap.

22.Raise the vehicle on the hoist to full height.

23.Remove the front tyres/wheels.

24.Remove the splash shield.

 

25.Loosen the drain plug in the radiator, and drain the engine coolant.

26.Drain the transmission fluid:


27.Drain the engine oil.

28.Disconnect the primary heated oxygen sensor (primary HO2S) connector (A) (K20A4 engine (KU, KZ, FO, PH, MA, KN, KM, IN, models)), or air fuel ratio sensor connector (A) (K24A1, K20A4 (KE, KG, KS models) engines).

 

29.Disconnect the secondary heated oxygen sensor (secondary HO2S) connector (B) (K24A1, K20A4 (KE, KG, KS models) engines), (C) (K20A4 engine (KU, KZ, FO, PH, MA models)).

30.Remove the three way catalytic converter (TWC) assembly (D).

31.Separate the propeller shaft from the transfer (4WD models).

32.Disconnect the stabilizer links.

33.Disconnect the suspension lower arm ball joints.

34.Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.

35.Remove the shift cable (A/T):


36.Remove the lower hose.

 

37.Remove the ATF filter mounting bolt (A) (A/T).

 

38.Remove the ATF cooler hoses (B), then plug the ATF cooler hoses and lines (A/T).

39.Lower the vehicle on the hoist.

40.Remove the upper hose (A) and heater hoses (B).

 


41.Attach the engine tilt hanger set (Commercially available tool for EU models) to the engine as shown.

 

42.Remove the transmission mount bracket support bolt/nuts.

M/T: 

A/T: 

43.Remove the upper bracket mounting bolt and nut.

 

44.Make sure the hoist brackets are positioned properly. Raise the vehicle on the hoist to full height.

45.Remove the rear mount mounting bolts.

 

46.Remove the front mount mounting bolt.

 

47.Use a marker to make alignment marks on the reference lines (A) that align with the centers of the rear subframe mounting bolts (B).

 

48.Remove the front subframe (C).

49.Disconnect the compressor clutch connector (A), then remove the A/C compressor (B) without disconnecting the A/C hoses.

 

50.Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.

51.Slowly lower the engine/transmission assembly about 150 mm (6 in.). Check once again that all hoses and wires are disconnected from the engine/transmission.

52.Lower the engine all the way. Remove the chain hoist from the engine.

53.Remove the engine/transmission assembly from under the vehicle.