ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. PRECAUTION

    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

    After turning the engine 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

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  5. SECURE STEERING WHEEL

  6. REMOVE FRONT WHEELS

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH


    1. Remove the 3 screws and front wheel opening extension pad RH.

  9. REMOVE ENGINE UNDER COVER RH


    1. Remove the 2 screws, 3 clips and engine under cover RH.

  10. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH


    1. Remove the 3 screws and front wheel opening extension pad LH.

  11. REMOVE ENGINE UNDER COVER LH


    1. Remove the 2 screws, 2 clips and engine under cover LH.

  12. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 2 bolts, clip and front fender apron seal LH.

  13. REMOVE FRONT FENDER APRON SEAL RH


    1. Remove the 2 bolts, clip and front fender apron seal RH.

  14. DRAIN ENGINE OIL

    Click here

  15. DRAIN ENGINE COOLANT

    Click here

  16. DRAIN AUTOMATIC TRANSAXLE FLUID

    Click here

  17. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  18. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B001O32

      Lift the rear of the No. 1 engine cover sub-assembly to detach it from the 2 pins.

    2. Lift the front of the No. 1 engine cover sub-assembly to detach the it from the pin and remove it.

      Note

      Attempting to disengage both front and rear pins at the same time may cause the No. 1 engine cover sub-assembly to break.

  19. REMOVE INLET AIR CLEANER ASSEMBLY


    1. B001OA9

      Remove the 2 bolts and inlet air cleaner assembly.

  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B001OBL

      Disconnect the wire harness clamp.

    2. Remove the 2 bolts and air cleaner case sub-assembly.

  23. REMOVE BATTERY


    1. B001O5N

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

    2. Loosen the nut, and remove the bolt and battery clamp.

    3. Remove the battery and battery tray.

  24. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    Click here

  25. DISCONNECT NO. 1 RADIATOR HOSE


    1. B001OD3

      Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.

    2. Slide the clip and disconnect the No. 1 radiator hose.

  26. DISCONNECT NO. 2 RADIATOR HOSE


    1. B001NOW

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

  27. DISCONNECT INLET HEATER WATER HOSE


    1. B001NVV

      Slide the clip and disconnect the inlet heater water hose.

  28. DISCONNECT OUTLET HEATER WATER HOSE B


    1. B001O9WE02
      Text in Illustration
      *1 Inlet Heater Water Hose
      *2 Outlet Heater Water Hose A
      *3 Outlet Heater Water Hose B

      Disengage the 2 claws and disconnect the inlet heater water hose and outlet heater water hose A.

    2. Slide the clip and disconnect the outlet heater water hose B.

  29. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B001OB0

      Slide the clip and disconnect the No. 4 water by-pass hose.

  30. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. B001O7A

      Disconnect the breather plug from the No. 3 water by-pass hose.

    2. Slide the clip and disconnect the No. 3 water by-pass hose.

  31. REMOVE STARTER ASSEMBLY

    Click here

  32. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. B001OBD

      Remove the 2 nuts and disconnect the wire clamp.

    3. Using a screwdriver, unlock the clamp and separate the engine wire from the engine room relay block.

    4. B001O7E

      Disconnect the 4 connectors.

    5. Using a screwdriver, unlock the clamp and separate the engine wire from the engine room relay block.

    6. B001NZC

      Pull up the lever to disconnect the ECM connector.

    7. Disconnect the 2 wire clamps.

  33. REMOVE NO. 1 AIR CLEANER BRACKET


    1. B001NRC

      Disconnect the 2 wire clamps.

    2. Remove the bolt and No. 1 air cleaner bracket.

  34. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B001O2K

      Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

    2. B001NYG

      Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.

  35. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. B001NV1

      Remove the 2 bolts and No. 2 engine mounting stay RH.

  36. DISCONNECT EARTH WIRE


    1. B001O78

      Remove the bolt to disconnect the earth wire from the engine moving control rod bracket.

  37. REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. B001O17

      Remove the 4 bolts and engine moving control rod bracket.

  38. REMOVE ENGINE MOVING CONTROL ROD


    1. B001O0X

      Remove the bolt, engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket.

      Tech Tips

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  39. DISCONNECT UNION TO VACUUM TUBE HOSE (for LHD)


    1. B001OEO

      Slide the clip and disconnect the union to vacuum tube hose.

  40. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. B001OHR

      Slide the clip and disconnect the union to check valve hose.

  41. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  42. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  43. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  44. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  45. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  46. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  47. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  48. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  49. SEPARATE FRONT SPEED SENSOR LH

    Click here

  50. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  51. SEPARATE TIE ROD ASSEMBLY LH

    Click here

  52. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  53. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  54. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  55. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  56. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  58. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  59. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  60. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  61. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. B001NUL

      Remove the flywheel housing under cover.

  62. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  63. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B001OPT

      Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle.

      Text in Illustration
      B001NZR Attachment Installation Position

      Note


      • Install height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

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

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

      • 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 or removed from an engine stand.

    2. B001O75

      Remove the 4 bolts, 2 nuts and frame side rail plate RH and frame side rail plate LH.

    3. Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and front suspension member brace rear LH.

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

      Note


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

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

    5. Install the engine hangers Click here.

    6. Using an engine sling device and engine lift, secure the engine assembly.

  64. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly with transaxle.

  65. REMOVE V-RIBBED BELT

    Click here

  66. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  67. REMOVE GENERATOR ASSEMBLY

    Click here

  68. REMOVE FRONT FRAME ASSEMBLY


    1. B001O13

      Remove the nut and separate the engine mounting insulator LH.

    2. B001NSK

      Remove the bolt and separate the front engine mounting insulator.

    3. B001NVL

      Remove the nut and separate the engine mounting insulator RH.

    4. Remove the front frame assembly.

    5. Using height adjustment attachments and plate lift attachments, place the engine assembly on a flat level surface.

      Note


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

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

      • Using an engine sling device and engine lift, secure the engine assembly before service.

  69. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B001OQS

      Remove the 3 nuts and front engine mounting insulator.

      Tech Tips

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

  70. REMOVE ENGINE MOUNTING INSULATOR LH


    1. B001OHL

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 3 nuts and engine mounting insulator LH.

      Tech Tips

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

  71. REMOVE ENGINE MOUNTING INSULATOR RH


    1. B001O4W

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 3 nuts and engine mounting insulator RH.

      Tech Tips

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

  72. REMOVE DRIVE SHAFT BEARING BRACKET


    1. B001NNK

      Remove the 3 bolts and drive shaft bearing bracket.

  73. REMOVE ENGINE MOUNTING BRACKET RH


    1. B001NRK

      Remove the 3 bolts and engine mounting bracket RH.

  74. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  75. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  76. INSTALL ENGINE STAND


    1. Install the engine to an engine stand with the bolts.