Part 1

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL (STEPS 1-41)

1. REMOVE COOL AIR INTAKE DUCT SEAL
a. Remove the 11 clips and intake duct seal.

2. REMOVE ENGINE ROOM SIDE COVER LH
a. Remove the 5 clips and side cover.

3. REMOVE ENGINE ROOM SIDE COVER RH
a. Remove the 2 clips and side cover.

4. REMOVE V-BANK COVER SUB-ASSEMBLY
a. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.

NOTICE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.

5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
6. DISCHARGE FUEL SYSTEM PRESSURE
7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
9. REMOVE FRONT WHEEL
10. REMOVE ENGINE UNDER COVER
11. REMOVE NO. 2 ENGINE UNDER COVER

12. REMOVE ENGINE UNDER COVER REAR LH
a. Remove the bolt and engine under cover LH.
13. REMOVE ENGINE UNDER COVER REAR RH

HINT: Remove the RH side following the same procedures as with the LH side.

14. DRAIN ENGINE OIL
15. DRAIN ENGINE COOLANT
16. REMOVE FRONT EXHAUST PIPE ASSEMBLY
17. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

18. REMOVE NO. 1 INLET AIR CLEANER
a. Remove the bolt, clip and inlet air cleaner.
19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
a. Remove the 2 bolts, clamp and air cleaner case.
21. DISCONNECT UNION TO CHECK VALVE HOSE
a. Remove the clamp and disconnect the union to check valve hose.

22. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE
a. Remove the clamp and disconnect the No. 2 fuel vapor feed hose.

23. DISCONNECT INLET RADIATOR HOSE
a. Remove the clamp and disconnect the inlet radiator hose.
24. DISCONNECT OUTLET RADIATOR HOSE
a. Remove the clamp and disconnect the outlet radiator hose.
25. DISCONNECT RADIATOR RESERVOIR TANK HOSE
a. Remove the clamp and disconnect the radiator reservoir tank hose.

26. DISCONNECT INLET HEATER WATER HOSE
a. Disconnect the inlet heater water hose.

27. DISCONNECT OUTLET HEATER WATER HOSE
a. Disconnect the outlet heater water hose.
28. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE
29. REMOVE DISCHARGE HOSE SUB-ASSEMBLY
30. REMOVE ECM COVER
31. DISCONNECT ENGINE WIRE
a. Disconnect the 6 ECM connectors.

b. Using a screwdriver, disconnect the connector holder.
c. Remove the engine room No. 1 relay block cover.

d. Remove the nut and disconnect the wire from the engine room No. 1 junction block.
e. Remove the nut and disconnect the battery positive (+) cable.
f. Disconnect the connector and remove the 4 clamps from body

g. Remove the bolt, clamp and engine wire No. 3.
h. Remove the bolt and disconnect the ground cable.
32. DISCONNECT FUEL MAIN TUBE

33. DISCONNECT NO. 3 FUEL HOSE
a. Remove the clamp and disconnect the No. 3 fuel hose.
34. DISCONNECT FUEL TUBE SUB-ASSEMBLY

a. Remove the fuel pipe clamp.

b. Pinch and pull the fuel tube's connector to disconnect it from the fuel tube sub-assembly.

NOTICE:
^ Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel main pipe.
^ Do not use any tools to separate the connector and pipe.
^ Do not forcefully bend or twist the hose.
^ Keep the connector and pipe free from foreign matter.
^ If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
^ Put the connector in a plastic bag to prevent damage and contamination.

35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR
a. Remove the 4 bolts and suspension member protector.
36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

37. DISCONNECT HEIGHT CONTROL SENSOR LINK
a. Remove the nut and disconnect the height control sensor link.

38. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH
a. Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.
39. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH

HINT: Remove the RH side following the same procedures as for the LH side.

40. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH
a. Remove the 2 bolts from the front lower ball joint.
41. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH

HINT: Remove the RH side following the same procedures as for the LH side.