ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle assembly is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE

  1. PRECAUTION

    Note:

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

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  3. REMOVE RADIATOR ASSEMBLY

    Click here

  4. REMOVE FRONT LOWER BUMPER ABSORBER

    1. Remove the 4 bolts and front lower bumper absorber.

    2. Remove the 2 hooks of the front lower bumper absorber from the installation holes in the body and remove the front lower bumper absorber.

  5. REMOVE NO. 1 ENGINE COVER

    1. A321275N01

      Lift the No. 1 engine cover to detach the 4 clips in the sequence shown in the illustration and remove the No. 1 engine cover.

      Note:

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

  6. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  7. REMOVE OUTER COWL TOP PANEL

  8. REMOVE CENTER NO. 4 ENGINE UNDER COVER (w/ Cover)

    1. Remove the 2 clips and center No. 4 engine under cover.

  9. REMOVE NO. 2 ENGINE UNDER COVER

    1. Remove the 4 clips and No. 2 engine under cover.

  10. REMOVE REAR ENGINE UNDER COVER LH

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

  11. REMOVE REAR ENGINE UNDER COVER RH

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

  12. DRAIN ENGINE OIL

    Click here

  13. DRAIN MANUAL TRANSAXLE OIL

    Click here

  14. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  15. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  16. REMOVE BATTERY

    1. Loosen the nut and disconnect the cable from the positive (+) battery terminal.

    2. A313616

      Remove the bolt, nut, battery clamp bolt and battery clamp sub-assembly.

    3. A354316

      Remove the battery insulator from the battery.

    4. Remove the battery.

    5. A354314

      Remove the battery and battery tray.

  17. REMOVE BATTERY CARRIER

    1. A354313

      Disengage the 2 clamps.

    2. Remove the 4 bolts and battery carrier.

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

    Click here

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

    Click here

  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  22. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    1. A319846

      Slide the clamp and disconnect the water by-pass hose assembly from the radiator reserve tank assembly.

    2. Slide the clamp and disconnect the No. 2 water by-pass hose assembly from the radiator reserve tank assembly.

    3. Remove the 2 bolts and radiator reserve tank assembly.

  23. REMOVE WATER BY-PASS HOSE ASSEMBLY

    1. A319847

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 1 air tube assembly.

    2. A318482

      Remove the water by-pass hose assembly from the water by-pass pipe.

  24. REMOVE RADIATOR HOSE SUB-ASSEMBLY

    1. A319848

      Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 air tube assembly.

    2. A319849

      Remove the radiator hose sub-assembly from the water outlet.

  25. DISCONNECT VACUUM HOSE

    1. A318485

      Slide the clamp and disconnect the vacuum hose from the No. 2 vacuum hose assembly.

  26. DISCONNECT NO. 2 FUEL HOSE

    1. A356187

      Disconnect the No. 2 fuel hose from the fuel feed pipe sub-assembly.

  27. DISCONNECT FUEL HOSE

    1. A356188

      Disconnect the fuel hose from the fuel feed pipe sub-assembly.

  28. DISCONNECT WATER HOSE SUB-ASSEMBLY

    1. A354306

      Slide the clamp and disconnect the water hose sub-assembly from the No. 1 air tube assembly.

  29. DISCONNECT OUTLET HEATER WATER HOSE

    1. A354307

      Slide the clamp and disconnect the outlet heater water hose from the No. 1 air tube assembly.

  30. DISCONNECT ENGINE WIRE

    1. Remove the No. 1 engine room relay block cover.

    2. A318488

      Disconnect the 2 connectors.

    3. Remove the 2 nuts.

    4. Detach the 2 claws to disconnect the engine wire from the No. 1 engine room relay block.

    5. A318483

      Remove the bolt to disconnect the ground cable.

  31. REMOVE FUEL FILTER ASSEMBLY

    Click here

  32. REMOVE GLOW PLUG RELAY ASSEMBLY

    1. Remove the bolt and separate the glow plug relay assembly from the fuel filter support.

    2. Disengage the wire harness clamp from the fuel filter support.

  33. REMOVE FUEL FILTER SUPPORT

    1. A318487

      Raise the lever while pushing the lock on the lever, and 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. A318490

      Disconnect the connector.

    3. Detach the 2 clamps to disconnect the engine wire.

    4. A358353

      Detach the clamp to disconnect the wire harness.

    5. Remove the 3 bolts and fuel filter support.

  34. REMOVE AIR CLEANER BRACKET

    1. A318492

      Remove the 3 bolts and air cleaner bracket.

  35. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  36. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  37. SECURE STEERING WHEEL

    Click here

  38. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  39. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  40. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  41. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

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

    Click here

  43. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  44. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tip:

    Perform the same procedure as for the LH side.

  45. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  46. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  47. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  48. 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 crossmember 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. A358309

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

    3. A318501

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A318380

      Detach the clamp and disconnect the air conditioner tube and accessory assembly.

    5. Detach the 2 clamps and disconnect the suction pipe sub-assembly.

    6. A318496

      Remove the 4 bolts, 3 nuts and engine mounting insulator sub-assembly RH.

    7. A318495

      Remove the bolt and nut to remove the engine mounting insulator LH.

      Tip:

      While holding the bolt in place, loosen the nut.

    8. 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.

    9. Using an engine sling device and engine lift, secure the engine assembly with transaxle.

      Note:

      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedures 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.

  49. REMOVE ENGINE WIRE

    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine assembly, and then remove the bracket bolts and engine wire from the engine assembly.

  50. REMOVE NO. 1 AIR TUBE ASSEMBLY

    1. Disconnect the compressor outlet elbow to the turbocharger sub-assembly.

    2. A339101

      Disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    3. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  51. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  52. REMOVE NO. 2 MANIFOLD STAY

    Click here

  53. REMOVE STARTER ASSEMBLY

    Click here

  54. REMOVE MANUAL TRANSAXLE ASSEMBLY

    1. C330944

      Remove the 6 bolts and manual transzxle assembly from the engine assembly.

  55. INSTALL ENGINE TO ENGINE STAND

    Note:

    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.

    1. Install the engine assembly to an engine stand, and remove the sling device and chain block from the engine assembly.

  56. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A358308

      Remove the bolt, nut and front engine mounting insulator.

      Tip:

      When removing the bolt, keep the nut from rotating.

  57. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A358310

      Remove the bolt to remove the rear engine mounting insulator.

  58. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A318508

      Remove the 4 bolts and engine mounting insulator LH from the vehicle body.