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.

Note:

When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

  3. DISCHARGE FUEL SYSTEM PRESSURE

  4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  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

  7. REMOVE FRONT LOWER BUMPER ABSORBER

    1. Remove the 8 bolts, 4 screws and front lower bumper absorber.

  8. REMOVE NO. 1 ENGINE UNDER COVER (for Half Cover Type)

    1. Remove the 2 bolts, 7 clips and No. 1 engine under cover.

  9. REMOVE NO. 1 ENGINE UNDER COVER (for Metal Type)

    1. Remove the 5 bolts, 2 clips and No. 1 engine under cover.

  10. REMOVE CENTER NO. 4 ENGINE UNDER COVER

    1. Remove the 5 clips and center No. 4 engine under cover.

  11. REMOVE REAR ENGINE UNDER COVER LH

    1. Remove the 5 clips and rear engine under cover LH.

  12. REMOVE REAR ENGINE UNDER COVER RH

    1. Remove the 5 clips and rear engine under cover RH.

  13. DRAIN ENGINE OIL

  14. DRAIN ENGINE COOLANT

  15. DRAIN MANUAL TRANSAXLE OIL

  16. REMOVE NO. 1 ENGINE COVER

    1. A293279

      Disengage the 3 clips and remove the No. 1 engine cover.

      Note:
      • When removing the No. 1 engine cover, ensure that the No. 1 engine cover does not interfere with the outer cowl top panel.

      • Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

  17. REMOVE PURGE VALVE (PURGE VSV)

  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

    2. A186568

      Disconnect the engine wire harness clamp from the air cleaner case sub-assembly.

    3. Remove the 3 bolts and air cleaner case sub-assembly.

  20. REMOVE BATTERY

    1. A293280

      Loosen the nut, and separate the positive (+) battery terminal.

    2. Remove the bolt and loosen the nut.

    3. Remove the battery clamp sub-assembly and battery.

    4. Remove the battery tray from the battery carrier.

  21. DISCONNECT NO. 1 RADIATOR HOSE

    1. A293281

      Remove the 2 bolts and radiator pipe from the battery carrier.

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

  22. DISCONNECT NO. 2 RADIATOR HOSE

    1. A196104

      Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.

  23. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. C193810

      Remove the nut and disconnect the clip, clamp and wire harness.

    2. A297327N01

      Remove the 2 clips (A) and disconnect the 2 transmission control cable assemblies from the manual transaxle.

    3. Remove the 2 clips (B) and disconnect the 2 transmission control cable assemblies from the control cable bracket.

    4. C274373

      Remove the bolt and disconnect the transmission control cable assembly from the rear engine mounting bracket.

  24. DISCONNECT UNION TO CONNECTOR TUBE HOSE (for LHD)

    1. A293283

      Slide the clip and disconnect the union to connector tube hose from the intake manifold.

  25. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (for RHD)

    1. A293284

      Slide the clip and disconnect the check valve to brake booster hose from the intake manifold.

  26. DISCONNECT HEATER WATER OUTLET HOSE A

    1. A199938

      Disconnect the 2 hose clamps.

    2. Slide the clip and disconnect the heater water outlet hose A from the No. 1 water by-pass pipe.

  27. DISCONNECT HEATER WATER INLET HOSE A

    1. A293263

      Disconnect the hose clamp.

    2. Slide the clip and disconnect the heater water inlet hose A from the cylinder head sub-assembly.

  28. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

  29. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

  30. DISCONNECT FUEL TUBE SUB-ASSEMBLY

  31. REMOVE V-RIBBED BELT

  32. DISCONNECT WIRE HARNESS

    1. A285510

      Pull up the lever to disconnect the ECM connector.

    2. Disconnect the wire harness clamp.

    3. Remove the No. 1 relay block cover from the engine room relay block and junction block assembly.

    4. A285512

      Remove the 2 nuts from the engine room relay block and junction block assembly.

    5. Disconnect the 3 connectors and wire harness from the engine room relay block and junction block assembly and disengage the 2 claws.

    6. A183913

      Disconnect the 2 wire harness clamps from the battery carrier.

    7. A293264

      Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.

  33. SECURE STEERING WHEEL

  34. REMOVE COLUMN HOLE COVER SILENCER SHEET

  35. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

  38. REMOVE FRONT DRIVE SHAFT ASSEMBLY

  39. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)

  40. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

  41. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tip:

    Perform the same procedure as for the LH side.

  42. DISCONNECT NO. 1 CLUTCH HOSE

    1. A196105

      Using a 10 mm union nut wrench, disconnect the No. 1 clutch hose from the bleeder clutch release tube.

    2. Remove the clip and disconnect the No. 1 clutch hose.

  43. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

  44. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  45. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

  46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. Set an engine lifter.

      Note:
      • Place height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

      • Do not position the height adjustment attachments or plate lift attachments under the front cross member sub-assembly.

      • 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.

    2. A295541

      Remove the 2 bolts to disconnect the front engine mounting insulator from the front cross member sub-assembly.

    3. A295542

      Remove the 4 bolts and front cross member sub-assembly.

    4. A293267C01

      *A

      Type A

      *B

      Type B

      Remove the bolt and 2 nuts and separate the engine mounting insulator RH.

    5. A293268

      Remove the through bolt and nut and separate the engine mounting insulator LH.

      Tip:

      When removing the through bolt, keep the nut from rotating.

    6. Carefully remove the engine assembly with transaxle from the vehicle.

      Note:

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

  47. INSTALL ENGINE HANGER

    1. A354320C01

      *1

      No. 1 Engine Hanger (12281-47023)

      *2

      No. 2 Engine Hanger (12282-47010)

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

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Part Name

      Part No.

      No. 1 engine hanger

      12281-47023

      No. 2 engine hanger

      12282-47010

      Bolt

      91552-81040

    2. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

  48. REMOVE FRONT ENGINE MOUNTING INSULATOR

    1. A293270

      Remove the through bolt, nut and front engine mounting insulator from the front engine mounting bracket.

      Tip:

      When removing the through bolt, keep the nut from rotating.

  49. REMOVE REAR ENGINE MOUNTING INSULATOR

    1. A354443C01

      *A

      Type A

      *B

      Type B

      Remove the through bolt and rear engine mounting insulator from the rear engine mounting bracket.

  50. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A293275

      Remove the 4 bolts and engine mounting insulator LH.

  51. REMOVE ENGINE MOUNTING INSULATOR RH

    Tip:

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

    1. A287994

      Remove the 2 bolts and disconnect the radiator reservoir tank.

    2. A293276C01

      *A

      Type A

      *B

      Type B

      Remove the bolt and cooler pipe clamp bracket from the engine mounting insulator RH.

    3. Disconnect the cooler pipe clamp from the engine mounting insulator RH.

    4. Remove the 3 bolts and engine mounting insulator RH.

  52. REMOVE FLYWHEEL HOUSING SIDE COVER

  53. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

  54. REMOVE GENERATOR ASSEMBLY (for 80 A Type)

  55. REMOVE GENERATOR ASSEMBLY (for 100 A Type)

  56. REMOVE STARTER ASSEMBLY

  57. DISCONNECT WIRE HARNESS

  58. REMOVE MANUAL TRANSAXLE ASSEMBLY

  59. REMOVE BLEEDER CLUTCH RELEASE TUBE

  60. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

  61. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

  62. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

  63. REMOVE CLUTCH COVER ASSEMBLY

  64. REMOVE CLUTCH DISC ASSEMBLY

  65. REMOVE FLYWHEEL SUB-ASSEMBLY

  66. REMOVE ENGINE WIRE

    1. A198275

      Remove the 2 nuts from the cylinder head cover sub-assembly.

    2. A293265

      Remove the bolt and wire harness bracket from the cylinder head cover sub-assembly.

    3. Remove the 3 bolts and nut from the cylinder head sub-assembly.

    4. Disconnect all the clamps and connectors, and remove the engine wire.

  67. 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.

  68. REMOVE ENGINE HANGER

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