Part 2

ENGINE ASSEMBLY REMOVAL Continued





52. DISCONNECT NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY
a. Fix the steering wheel with the seat belt in order to prevent rotation.

HINT: This operation is useful to prevent damage to the spiral cable.





b. Loosen bolt (A) and remove bolt (B), then slide the No.2 steering intermediate shaft.

HINT:
^ Do not remove bolt (A).
^ Do not disconnect the No.2 steering intermediate shaft from the power steering link.





c. Put matchmarks on the No.2 steering intermediate shaft and the power steering link.
d. Separate the No.2 intermediate shaft from the power steering link.

53. REMOVE ENGINE WITH TRANSMISSION ASSEMBLY
a. Set the engine lifter.





b. Remove the 4 bolts and disconnect the engine rear mounting member.





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

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

54. REMOVE ENGINE WIRE
55. REMOVE NO.1 OIL COOLER INLET TUBE
a. Remove the 2 bolts and clamps.





b. Loosen the union nut and remove the oil cooler inlet tube.





56. REMOVE NO.1 OIL COOLER OUTLET TUBE
a. Loosen the union nut and remove the oil cooler outlet tube.





57. DISCONNECT WIRE HARNESS AND CONNECTORS
a. Tilt down the automatic transmission.

NOTICE: Take care so that the cooling fan does not come into contact with the fan shroud.





b. Remove the 5 bolts and wire harness clamps.
c. Disconnect the park/neutral position switch connector.
d. Disconnect the transmission wire connector.
e. Disconnect the 2 speed sensor connectors.
f. Disconnect the wire harness from the automatic transmission.

HINT: Bolt (A) is tightened to the transmission housing.





58. REMOVE FLYWHEEL HOUSING UNDER COVER
a. Remove the 2 bolts and under cover.





59. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
a. Turn the crankshaft to gain access to each bolt.
b. Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.





c. Remove the 9 bolts.
d. Separate and remove the automatic transmission.





60. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
a. Remove the 8 bolts, rear spacer, ring gear and front spacer.

61. REMOVE OIL DIPSTICK GAUGE GUIDE
a. Remove the bolt, dipstick and O-ring.





62. REMOVE FRONT ENGINE MOUNTING INSULATOR
a. Remove the 2 bolts, then remove the front suspension crossmember sub-assembly from the engine.





63. REMOVE NO.1 EXHAUST MANIFOLD HEAT INSULATOR
a. Remove the 4 bolts and heat insulator.





64. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 8 nuts, exhaust manifold and gasket.





65. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.





66. REMOVE NO.2 EXHAUST MANIFOLD HEAT INSULATOR
a. Remove the 4 bolts and heat insulator.





67. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 8 nuts, exhaust manifold and gasket.





68. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.

69. REMOVE NO.2 WIRING HARNESS HEAT INSULATOR
a. Remove the 2 bolts and No.2 wiring harness heat insulator.

70. REMOVE ENGINE STAND
71. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Remove the manifold.

72. REMOVE NO.1 IDLER PULLEY BRACKET SUB-ASSEMBLY
73. REMOVE GENERATOR ASSEMBLY

LH Bank:

74. REMOVE NO.1 ENGINE HANGER
a. Remove the 2 bolts and engine hanger.

RH Bank:

75. REMOVE NO.2 ENGINE HANGER
a. Remove the 2 bolts and engine hanger.





76. REMOVE NO.3 TIMING BELT COVER SUB-ASSEMBLY RH
a. Remove the cap nut, 3 bolts, timing belt cover and gasket.





77. REMOVE NO.3 TIMING BELT COVER SUB-ASSEMBLY LH
a. Remove the cap nut and disconnect the No.3 water by-pass pipe from the timing belt cover.
b. Disconnect the 2 water by-pass hoses from the No.3 water by-pass pipe.
c. Disconnect the engine wire from the 2 wire clamps.
d. Disconnect the camshaft position sensor connector.
e. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
f. Remove the wire grommet from the timing belt cover.
g. Remove the 4 bolts.
h. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
i. Disconnect the wire clamp for the sensor from the timing belt cover.
j. Remove the connector holder from the sensor connector.
k. Remove the timing belt cover.

78. REMOVE WATER INLET HOUSING
a. Remove the 2 bolts and inlet housing.





79. REMOVE FRONT WATER BY-PASS JOINT
a. Disconnect the ECT sensor connector.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.





80. REMOVE REAR WATER BY-PASS JOINT
a. Disconnect the heater inlet hose from the water bypass joint.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.

81. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Disconnect the heater outlet hose from the water by-pass pipe.
b. Disconnect the wire clamp (for knock sensor 1, 2) from the bracket of the water by-pass pipe.
c. Remove the bolt.
d. Pull out the water by-pass pipe from the water pump.
e. Remove the O-ring from the water by-pass pipe.

82. REMOVE STARTER ASSEMBLY
83. REMOVE OIL FILLER CAP HOUSING
a. Remove the 2 nuts and housing.

84. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Disconnect the 2 sensor connectors.
b. Remove the 2 bolts and 2 oil control valves.

85. REMOVE CAMSHAFT POSITION SENSOR
a. Disconnect the sensor connector.
b. Remove the bolt and sensor.

86. REMOVE VVT SENSOR
a. Disconnect the 2 sensor connectors.
b. Remove the 2 bolts and sensors.

87. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the sensor connector.
b. Remove the bolt and sensor.

88. REMOVE KNOCK SENSOR
a. Disconnect the 2 sensor connectors.
b. Remove the 2 sensors.

89. REMOVE IGNITION COIL
a. Remove the 8 bolts and 8 ignition coils.

90. REMOVE OIL PRESSURE SWITCH
a. Disconnect the oil pressure switch connector.





b. Using a 24 mm deep socket wrench, remove the oil pressure switch.

91. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Disconnect the oil pressure switch connector.
b. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.

92. REMOVE ENGINE OIL LEVEL SENSOR
a. Disconnect the sensor connector.
b. Remove the 4 bolts, sensor and gasket.

93. REMOVE NO.1 ENGINE MOUNTING BRACKET FRONT RH
a. Remove the 4 bolts and mounting bracket.

94. REMOVE NO.1 ENGINE MOUNTING BRACKET FRONT LH
a. Remove the 4 bolts and mounting bracket.