1. Set the vehicle on a lift.
2. Change the hood support stay bolt mounting position from (A) to (B), and completely open the front hood.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
3. Remove the battery. 
4. Remove the collector cover.
5. Disconnect the generator harness.
(1) Disconnect the connector and B terminal.
(2) Disconnect the connector from the A/C compressor.
(3) Remove the harness from the collector cover bracket, and move aside to a position rear of the headlight (LH).
6. Remove the air intake duct (rear).
7. Remove the air cleaner element and the air cleaner case (rear).
8. Remove the intercooler body and the intercooler stay.
9. Disconnect the engine harness connectors, then remove the engine harness bracket.
10. Remove the air duct hose from the throttle body.
11. Disconnect the terminal S connector and terminal B from the starter, and remove the starter.
12. Remove the starter harness and engine ground bracket, and the fuel return pipe bracket.
NOTE:
On RHD model, remove the starter harness and engine ground bracket.
13. Disconnect the brake booster vacuum hose.
14. Recollect the refrigerant from the A/C system, and disconnect the high pressure pipe and low pressure pipe from the A/C compressor.
15. Lift up the vehicle.
16. Remove the under cover.
17. Remove the engine ground (LH) from the frame.
18. Remove the catalytic converter and DPF.
19. Drain the engine coolant.
20. Disconnect the radiator outlet hose from the radiator.
21. Disconnect the radiator main fan and radiator sub fan connectors.
• Radiator main fan
• Radiator sub fan
22. Remove the air intake duct and air intake boot.
|
(A) |
Air duct hose |
(B) |
Air intake duct |
23. Remove the engine ground (RH) from the frame.
24. Remove the connecting bolts and nuts (lower side) between the transmission and engine.
25. Remove the exhaust manifold (LH), turbocharger, and exhaust manifold (RH).
NOTE:
• It is possible to remove the engine from the vehicle without removing the exhaust manifold (LH), turbocharger, and exhaust manifold (RH) from the engine.
• When performing disassembly maintenance work on a ST engine stand (ST 499817100) after removing the engine from the vehicle, this procedure is performed.
26. Remove the engine mounting connecting nuts and washers.
27. Lower the vehicle.
28. Separate the air breather hose from the air intake boot, and remove the air intake boot.
29. Remove the air intake boot bracket.
30. Disconnect radiator inlet hoses LH and RH on the radiator side.
NOTE:
Without disconnecting hoses on the cylinder head side, hold the radiator inlet hose to the engine using ropes or equivalent.
31. Remove the reservoir tank.
32. Remove the radiator sub fan motor assembly.
33. Remove the radiator main fan motor assembly.
34. Remove the radiator.
35. Remove the heater hose.
36. Disconnect the fuel delivery hose and fuel return hose.
CAUTION:
• Be careful not to spill fuel.
• Catch the fuel from hoses using a container or cloth.
• To prevent foreign objects from entering the fuel delivery and fuel return hoses, plug the hoses with a cap, etc.
37. Disconnect the fuel injector connectors of all cylinders and affix the harnesses and connectors on intake manifold side.
CAUTION:
To prevent damage to the fuel injector connectors and harnesses, make sure to perform this step.
38. Support the engine with a lifting device and wire ropes.
39. Support the transmission lower side with a garage jack.
CAUTION:
Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
40. Separate the engine and transmission.
(1) Remove the connecting bolts (upper side) between the transmission and engine.
(2) Hold in place with the lifter slightly raised, so that the front cushion rubber stud bolt is drawn out of the crossmember.
(3) Move the engine horizontally towards the front of the vehicle to withdraw the main shaft from the clutch disc.
NOTE:
Perform work while making sure that the engine and vehicle body are not hitting with each other.
(4) Lift the engine and remove from the vehicle.
41. Remove the front cushion rubber from the engine.