ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Battery terminal is disconnected/reconnected Memorize steering angle neutral point LKA/LDA System

Click here

Pre-crash safety system

Lighting system (EXT)


  • Cornering lights
Adaptive high beam system
Drive the vehicle until stop and start control is permitted (approximately 15 to 60 minutes) Stop and start system

Click here

Memorize steering angle neutral point Parking Assist Monitor System (w/ Parallel Parking Assist Function)

Click here

Parking Assist Monitor System (w/o Parallel Parking Assist Function)

Click here

Panoramic view monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Reset back door close position Power back door system

Click here

Replacement of ECM Perform Vehicle Identification Number (VIN) or frame number registration

  • MIL illuminates / -

  • DTC P063051 is stored

Click here

ECU Communication ID Registration (Immobiliser system) Engine start function See Service Bulletin for the registration method.

  • Replacement of engine assembly

  • Gas leak from exhaust system is repaired

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

Replacement of starter assembly*1

Note

When the starter assembly is replaced, "ST relay" and "ST NO. 2 relay" must be also replaced.

 Clear Number of Starter Operations Stop and start system

Click here

Replacement of battery*1

  • Integrated Current Value Initialization

  • Switch Battery Type

  • Replacement of automatic transaxle assembly*1

  • Replacement of automatic transaxle fluid*1

 Bleed the oil pump assembly with motor (continuously variable transaxle assembly)
Replacement of automatic transaxle assembly

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Input Transaxle Compensation Code into ECM

  3. Perform Road Test to Allow ECM to Learn

  • Large shift shock

  • Deterioration of fuel efficiency

Click here for Initialization (U661E)

Click here for Registration (U661E)

Click here for Initialization (U661F)

Click here for Registration (U661F)

Replacement of ECM

(If possible, read the transaxle compensation code from the previous ECM)

 Possible to read transaxle compensation code

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Transfer Transaxle Compensation Code

  3. Perform Road Test to Allow ECM to Learn
Impossible to read transaxle compensation code

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Reset Transaxle Compensation Code

  3. Perform Road Test to Allow ECM to Learn
Suspension, tires, etc.*2 Rear television camera assembly optical axis (Back camera position setting) Parking assist monitor system (w/ Parallel Parking Assist Function)

Click here for Initialization

Click here for Calibration
Parking assist monitor system (w/o parallel parking assist function)

Click here for Initialization

Click here for Calibration

  • Parking assist ECU initialization

  • Adjust steering angle

 Panoramic view monitor system

Click here for Initialization

Click here for Calibration
Initialize headlight ECU sub-assembly LH

  • Adaptive high beam system

  • Automatic headlight beam level control system

Click here

Front wheel alignment adjustment

  1. Clearing zero point calibration data and system information.

  2. Perform yaw rate and acceleration sensor zero point calibration and store system information.

  • VSC disabled or malfunctions

  • DTCs are stored

  • Slip indicator light illuminates

  • ABS warning light illuminates

  • Theft deterrent system (tilt sensor)*3

Click here

*1: w/ Stop and Start System
*2: The vehicle height changes because of suspension or tire replacement
*3: w/ TFT Meter Type

CAUTION:


  • B005LB6C01
    *a An Object Exceeding Weight Limit of Engine Lifter

    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 or the engine assembly with transaxle may fall off the engine lifter.

  • B005LCC

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. SECURE STEERING WHEEL

    Click here

  5. PRECAUTION

    Note

    After turning the engine 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.

    Click here

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  7. REMOVE FRONT WHEELS

    Click here

  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH


    1. Remove the 2 screws and front wheel opening extension pad LH.

  9. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH


    1. Remove the 2 screws and front wheel opening extension pad RH.

  10. REMOVE NO. 3 ENGINE UNDER COVER


    1. B005NB2C01
      B005NIZ Bolt
      B005LWS Screw

      Remove the 5 bolts, 2 screws, 2 clips and No. 3 engine under cover.

  11. REMOVE NO. 1 ENGINE UNDER COVER


    1. B005MHLC01
      B005NIZ Bolt
      B005LWS Screw

      Remove the 3 bolts, 2 screws, clip and No. 1 engine under cover.

  12. REMOVE FRONT LOWER BUMPER ABSORBER


    1. B005PHDC01
      B005NIZ Screw
      B005LWS Clip

      Remove the 4 screws, 2 clips and disengage the 2 claws to remove the front lower bumper absorber.

  13. REMOVE FRONT FENDER APRON SEAL LH


    1. B005N8O

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

  14. REMOVE FRONT FENDER APRON SEAL RH

    B005LLI

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

  15. REMOVE NO. 2 ENGINE UNDER COVER


    1. B005N33C01
      B005NIZ Bolt
      B005LWS Screw

      Remove the 2 bolts, 2 screws, clip and No. 2 engine under cover.

  16. REMOVE FRONT FLOOR COVER LH

    Click here

  17. DRAIN ENGINE COOLANT

    Click here

  18. DRAIN COOLANT (for Intercooler)

    Click here

  19. DRAIN ENGINE OIL

    Click here

  20. DRAIN TRANSFER OIL (for AWD)

    Click here

  21. DRAIN AUTOMATIC TRANSAXLE FLUID

    for 2WD: Click here

    for AWD: Click here

  22. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  23. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B005OY3

      Disengage the 3 clips and No. 1 engine cover sub-assembly.

      Note

      When removing the No. 1 engine cover sub-assembly, make sure to lift it upward. Pulling the No. 1 engine cover sub-assembly towards you may damage the No. 1 engine cover sub-assembly.

  24. REMOVE BATTERY

    Click here

  25. REMOVE BATTERY CARRIER SUB-ASSEMBLY


    1. w/ NO. 3 Battery Clamp:


      1. B005OYJ

        Disengage the 3 clamps and disconnect the wire harness from the battery carrier sub-assembly.

      2. B005PG2

        Remove the 2 bolts and No. 3 battery clamp.

      3. B005PUE

        Remove the 4 bolts and battery carrier sub-assembly.

    2. w/o NO. 3 Battery Clamp


      1. B005NCB

        Disengage the 3 clamps and disconnect the wire harness from the battery carrier sub-assembly.

      2. B005NJU

        Remove the 6 bolts and battery carrier sub-assembly.

  26. REMOVE BATTERY BRACKET REINFORCEMENT


    1. B005Q54

      Remove the 2 bolts and battery bracket reinforcement.

  27. REMOVE INLET AIR CLEANER ASSEMBLY


    1. B005PUX

      Remove the 2 bolts and inlet air cleaner assembly.

  28. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  31. REMOVE AIR CLEANER BRACKET

    Click here

  32. REMOVE ECM

    Click here

  33. REMOVE INTERCOOLER RESERVE TANK ASSEMBLY


    1. B005NHJ

      Remove the 2 bolts.

    2. B005PT3C01
      *1 No. 1 Turbo Water Hose
      *2 No. 1 Intercooler Cooling Water Hose
      *3 No. 4 Intercooler Cooling Water Hose

      Slide the clip and disconnect the No. 1 turbo water hose from the intercooler reserve tank assembly.

    3. Slide the clip and disconnect the No. 4 intercooler cooling water hose from the intercooler reserve tank assembly.

    4. Slide the clip, disconnect the No. 1 intercooler cooling water hose from the intercooler reserve tank assembly and remove the intercooler reserve tank assembly.

  34. REMOVE INTAKE AIR CONNECTOR

    Click here

  35. REMOVE NO. 2 AIR CLEANER HOSE

    Click here

  36. REMOVE NO. 5 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  37. REMOVE OUTLET COMPRESSOR ELBOW

    Click here

  38. REMOVE INTAKE AIR RESONATOR

    Click here

  39. REMOVE NO. 1 AIR TUBE


    1. B005NSVC01
      *1 No. 2 Fuel Vapor Feed Hose
      *2 Fuel Tube Sub-assembly
      *3 No. 2 Fuel Tube Sub-assembly
      *4 No. 3 Ventilation Hose
      *5 Vacuum Switching Valve Hose Assembly
      *6 No. 1 Air Tube

      Disengage the 2 clamps to disconnect the No. 2 fuel vapor feed hose from the No. 1 air tube.

    2. Disengage the 2 clamps to disconnect the fuel tube sub-assembly and No. 2 fuel tube sub-assembly from the No. 1 air tube.

    3. Slide the clip and disconnect the No. 3 ventilation hose from the No. 1 air tube.

    4. Remove the bolt (A) and disconnect the vacuum switching valve hose assembly from the No. 1 air tube.

    5. Remove the 2 bolts (B).

    6. Loosen the clamp, then remove the No. 1 air tube from the intercooler assembly.

  40. SEPARATE NO. 3 INTERCOOLER COOLING WATER HOSE


    1. B005OIA

      Slide the clip and disconnect the No. 3 intercooler cooling water hose from the No. 3 intercooler cooling water pipe.

  41. DISCONNECT NO. 2 RADIATOR HOSE


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

  42. DISCONNECT NO. 1 RADIATOR HOSE


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

  43. DISCONNECT HEATER HOSE


    1. B005PEWC01
      *1 Inlet Heater Hose
      *2 Outlet Heater Hose

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

    2. Slide the clip and disconnect the outlet heater hose from the water hose sub-assembly.

  44. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  45. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  46. DISCONNECT ENGINE WIRE


    1. Remove the engine room relay block assembly.

    2. B005P4N

      Remove the nut, disengage the 2 engine wire clamps and disconnect the engine wire.

    3. B005MJT

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

    4. Disconnect the 3 connectors from the No. 1 engine room relay block and No. 1 junction block assembly.

    5. Disengage the 2 claws to disconnect the engine wire from the No. 1 engine room relay block and No. 1 junction block assembly.

    6. B005MATC01
      *a Battery State Sensor Assembly Connector
      *b Earth Wire

      Disconnect the battery state sensor assembly connector.

    7. Remove the bolt and disconnect the earth wire.

    8. B005QFL

      Remove the bolt and disconnect the No. 2 earth wire from the compressor assembly with pulley.

  47. REMOVE STARTER ASSEMBLY

    Click here

  48. DISCONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. B005L9T

      Slide the clip and disconnect the union to check valve hose from the vacuum switching valve hose assembly.

  49. DISCONNECT UNION TO CONNECTOR TUBE HOSE (for RHD)


    1. B005L9T

      Slide the clip and disconnect the union to connector tube hose from the vacuum switching valve hose assembly.

  50. DISCONNECT NO. 1 FUEL HOSE


    1. B005M0I

      Remove the No. 2 fuel pipe clamp from the fuel tube connector.

    2. B005N92

      Disconnect the No. 1 fuel hose from the 2 fuel pipes.

      Click here

  51. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. B005MIA

      Slide the clip and disconnect the fuel vapor feed hose assembly from the fuel pipe.

  52. DISCONNECT TRANSMISSION OIL COOLER


    1. B005Q8H

      Disengage the clamp and No. 1 breather plug (ATM) from the breather plug hose clamp.

    2. B005ORR

      Disconnect the 3 bolts and disconnect the transmission oil cooler from the front engine mounting bracket.

  53. REMOVE TRANSMISSION OIL THERMOSTAT

    for 2WD: Click here

    for AWD: Click here

  54. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B005PO9

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

    2. B005P2E

      Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket.

    3. B005NMW

      Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.

  55. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  56. REMOVE CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.


    1. B005PZT

      Disconnect the heated oxygen sensor connector.

    2. Disengage the 3 wire harness clamps.

    3. B005ORP

      Remove the 2 bolts and 2 compression springs and disconnect the tail exhaust pipe assembly from the center exhaust pipe assembly (TWC: Rear Catalyst).

    4. Remove the exhaust pipe gasket from the center exhaust pipe assembly (TWC: Rear Catalyst).

    5. Remove the center exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.

  57. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  58. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  59. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)

    Click here

  60. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. B005NXK

      Remove the flywheel housing under cover from the engine assembly.

  61. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    for 2WD: Click here

    for AWD: Click here

  62. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle level, set an engine lifter underneath the engine assembly with transaxle.

      Note


      • 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.

      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

    2. B005PEV

      Remove the bolt, nut and disconnect the engine mounting insulator LH from the engine mounting bracket LH.

    3. Type A:


      1. B005P5V

        Remove the 2 bolts, 2 nuts and disconnect the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    4. B005OFV

      Type B:


      1. Remove the bolt, 3 nuts and disconnect the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    5. B005Q46C01
      B005NIZ Bolt
      B005LWS Nut

      Remove the 6 bolts, 2 nuts and frame side rail plate sub-assembly RH and front suspension member bracket sub-assembly RH.

    6. Remove the 6 bolts, 2 nuts and frame side rail plate sub-assembly LH and front suspension member bracket sub-assembly LH.

    7. Operate the engine lifter to remove the engine assembly with transaxle from the vehicle.

      Note


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

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

  63. INSTALL ENGINE HANGER


    1. B005NORC03
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with the 3 bolts as shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-36100
      No. 2 Engine Hanger

      12282-36100

      12282-36101
      Bolt (No. 1 Engine Hanger) 91552-81050
      Bolt (No. 2 Engine Hanger) 91552-81025

    2. 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.

  64. REMOVE NO. 3 INTERCOOLER COOLING WATER PIPE


    1. B005L5ZC01
      *1 No. 5 Intercooler Cooling Water Hose
      *2 No. 2 Intercooler Cooling Water Hose
      *3 No. 2 Water By-pass Pipe

      Slide the clip and disconnect the No. 5 intercooler cooling water hose from the No. 2 water by-pass pipe.

    2. Slide the clip and disconnect the No. 2 intercooler cooling water hose from the No. 1 turbo water pipe sub-assembly.

    3. Remove the bolt and No. 3 intercooler cooling water pipe from the engine assembly.

  65. REMOVE NO. 2 INTERCOOLER COOLING WATER PIPE


    1. B005M23C01
      *1 No. 6 Intercooler Cooling Water Hose
      *2 No. 2 Water By-pass Pipe

      Slide the clip and disconnect the No. 6 intercooler cooling water hose from the No. 2 water by-pass pipe.

    2. Remove the bolt and No. 2 intercooler cooling water pipe from the engine assembly.

  66. DISCONNECT WIRE HARNESS

    for 2WD: Click here

    for AWD: Click here

  67. REMOVE FRONT NO. 1 STABILIZER BRACKET LH

    Click here

  68. REMOVE FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    Perform the same procedure as for the LH side.

  69. REMOVE FRONT STABILIZER BAR

    Click here

  70. REMOVE STEERING LINK ASSEMBLY

    Click here

  71. REMOVE TRANSFER STIFFENER PLATE RH (for AWD)

    Click here

  72. REMOVE FRONT FRAME ASSEMBLY


    1. B005NH1

      Disconnect the vacuum hose from the vacuum switching valve assembly.

    2. B005LQC

      Remove the bolt and separate the front engine mounting insulator from the front engine mounting bracket.

    3. B005Q0LC01
      *A for 2WD
      *B for AWD

      Remove the bolt and separate the rear engine mounting insulator with the front frame assembly from the rear engine mounting bracket.

  73. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

    for 2WD: Click here

    for AWD: Click here

  74. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  75. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B005LZM

      Remove the hole plug from the front frame assembly.

    2. Remove the 3 nuts and front engine mounting insulator from the front frame assembly.

  76. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B005OJN

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 4 nuts and rear engine mounting insulator.

  77. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. B005LESC01
      *1 Earth Wire
      *2 Cooler Compressor Bracket
      *3 Brake Actuator with Bracket

      Remove the bolt and earth wire from the engine mounting insulator sub-assembly RH.

    2. Remove the bolt and cooler compressor bracket from the engine mounting insulator sub-assembly RH.

    3. Remove the bolt and brake actuator with bracket from the vehicle body.

    4. B005OG6

      Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle body.

  78. REMOVE ENGINE MOUNTING SPACER

    Tech Tips

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


    1. B005OWD

      Remove the 2 bolts and engine mounting spacer.

  79. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B005P8C

      Remove the 5 bolts and engine mounting insulator LH from the vehicle body.

  80. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine to an engine stand.

  81. REMOVE ENGINE HANGERS


    1. Remove the 3 bolts, No. 1 engine hanger and No. 2 engine hanger.