ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. SECURE STEERING WHEEL

    Click here

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  6. REMOVE FRONT WHEELS

    Click here

  7. DRAIN ENGINE OIL

    Click here

  8. DRAIN ENGINE COOLANT

    Click here

  9. DRAIN MANUAL TRANSAXLE OIL

    for C550:Click here

    for C551:Click here

    for C553A:Click here

  10. REMOVE AIR CLEANER CAP

    1. A427502

      Disengage the 4 clamps and air cleaner cap.

  11. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    1. A427503

      Remove the air cleaner filter element sub-assembly.

  12. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    1. A427504C01

      *1

      Air Cleaner Cap Support

      *2

      No. 2 Ventilation Hose

      Remove the 2 bolts.

    2. Slide the clip of the No. 2 ventilation hose.

    3. Disengage the air cleaner case sub-assembly from the air cleaner cap support, No. 2 ventilation hose and cylinder head cover sub-assembly to remove it.

  13. REMOVE BATTERY

    1. w/ Stop And Start System:

      1. A426146

        Remove the nut and engine room main wire with the engine wire from the positive (+) battery terminal.

      2. Disengage the 2 claws to disconnect the engine room main wire from the engine wire.

    2. w/o Stop And Start System:

      1. A322536

        Remove the nut and engine room main wire with the engine wire from the positive (+) battery terminal.

      2. Disengage the 2 claws to disconnect the engine room main wire from the engine wire.

    3. A322357

      Remove the bolt and No. 2 battery clamp from the battery clamp sub-assembly.

    4. Remove the battery from the battery clamp sub-assembly.

  14. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    1. A322358

      Disengage the 5 wire harness clamps and disconnect the wire harness from the battery clamp sub-assembly.

    2. Remove the 5 bolts.

    3. Disengage the claw and remove the battery clamp sub-assembly from the No. 1 engine room relay block.

  15. REMOVE V-RIBBED BELT

    Click here

  16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    1. A421796

      Remove the bolt and V-ribbed belt tensioner assembly from the engine assembly.

  17. REMOVE GENERATOR ASSEMBLY

    for 80A Type:Click here

    for 100A Type:Click here

  18. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    1. A322359

      Disconnect the connector.

    2. Remove the 3 bolts and separate the compressor assembly with pulley.

      Tip:

      Secure the compressor and hoses off to the side instead of discharging the A/C system.

  19. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    1. A421797

      Disengage the claw and remove the No. 1 fuel pipe clamp.

    2. A421798

      Pinch the retainer shown in the illustration, then pull the fuel tube connector off the fuel pipe.

      Note:

      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them, as the fuel tube connector has O-rings that seal the fuel pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube sub-assembly.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  20. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

    A421799

    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).

  21. DISCONNECT OUTLET HEATER WATER HOSE

    Click here

  22. DISCONNECT INLET HEATER WATER HOSE

    Click here

  23. DISCONNECT NO. 1 RADIATOR HOSE

    A421800

    1. Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  24. DISCONNECT NO. 2 RADIATOR HOSE

    A421801

    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

  25. DISCONNECT ENGINE WIRE

    1. A322367

      Raise the lever while pushing the locks on the lever to disconnect the ECM connector.

      Note:

      After disconnecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the ECM connector.

    2. Disengage the wire harness clamp. (for LHD)

    3. A322375

      Remove the No. 1 engine room relay block cover.

    4. A322368

      Disconnect the 2 connectors from the No. 1 engine room relay block.

    5. Remove the nut.

    6. A322369

      Disengage the 2 claws and disconnect wire harness from the No. 1 engine room relay block.

    7. A322370

      Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.

    8. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the vehicle body and engine assembly with transaxle.

  26. REMOVE EGR VALVE WITH COOLER ASSEMBLY

    Click here

  27. REMOVE INTAKE MANIFOLD

    Click here

  28. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    for C550:Click here

    for C551:Click here

  29. DISCONNECT CLUTCH RELEASE CABLE ASSEMBLY

    for C550:Click here

    for C551:Click here

  30. REMOVE STEERING COLUMN HOLE COVER PLATE

    Click here

  31. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  32. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  33. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  34. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  35. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. A322512C02
      V100155

      Attachment Installation Position

      Set an engine lifter.

      Note:

      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

    2. A322513

      Remove the 2 bolts and nut, and separate the engine mounting insulator sub-assembly RH.

    3. A322514

      Remove the 3 bolts, and separate the engine mounting insulator LH.

    4. A322515

      Remove the 6 bolts, engine assembly with transaxle and front suspension crossmember sub-assembly from the vehicle body.

    5. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle body.

      Note:

      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While lowering the engine assembly with transaxle from the vehicle body, do not allow it to contact the vehicle body.

  36. INSTALL ENGINE HANGER

    1. A322516C01

      *1

      No. 1 Engine Hanger (Part No.12281-40032)

      *2

      No. 2 Engine Hanger (Part No.12282-40010)

      *a

      Bolt (Part No. 91551-80820 or 90105-W0112)

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

  37. SECURE ENGINE ASSEMBLY WITH TRANSAXLE

    1. Using an engine sling device and a chain block, hold the engine assembly with transaxle.

    2. To enable removal of the engine assembly with transaxle, adjust the positions of the height adjustment attachments and plate lift attachments and set them in place.

      Note:

      • Set the height adjustment attachments and plate lift attachments so that the engine assembly with transaxle is horizontal.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

    3. A421802

      Using a belt with a ratchet mechanism or a rope, secure the engine assembly with transaxle to the engine lifter.

      Note:

      • Do not tighten the belt with a ratchet mechanism or the rope any more than necessary.

      • Set the engine assembly with transaxle horizontally.

  38. REMOVE ENGINE WIRE

    1. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine assembly.

  39. REMOVE STARTER ASSEMBLY

    w/ Stop And Start System:Click here

    w/o Stop And Start System:Click here

  40. REMOVE NO. 1 DRIVE SHAFT HEAT INSULATOR

    1. C307952

      Remove the 2 bolts and No. 1 drive shaft heat insulator from the engine assembly.

  41. REMOVE ENGINE ASSEMBLY

    A322518

    1. Remove the 9 bolts and engine assembly from the transaxle.

  42. REMOVE FLYWHEEL HOUSING UNDER COVER

    1. A325626

      Remove the flywheel housing under cover from the oil pan sub-assembly.

  43. REMOVE CLUTCH COVER ASSEMBLY

    for C550:Click here

    for C551:Click here

    for C553A:Click here

  44. REMOVE CLUTCH DISC ASSEMBLY

    for C550:Click here

    for C551:Click here

    for C553A:Click here

  45. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  46. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A322519
    Tip:

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Remove the 3 bolts and engine mounting insulator sub-assembly RH from the vehicle body.

  47. REMOVE ENGINE MOUNTING INSULATOR LH

    A322520
    Tip:

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    1. Remove the 3 bolts and engine mounting insulator LH from the vehicle body.

  48. INSTALL ENGINE TO ENGINE STAND

    1. Install the engine assembly to an engine stand.

      Note:

      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

  49. REMOVE ENGINE HANGER

    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.