ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle 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 Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE FRONT WHEEL

  4. REMOVE ENGINE UNDER COVER LH

  5. REMOVE ENGINE UNDER COVER RH

  6. DRAIN ENGINE COOLANT

    Click here

  7. DRAIN MANUAL TRANSAXLE OIL

    Click here

  8. REMOVE BATTERY


    1. Disconnect the cable from the positive (+) battery terminal.

    2. A01VIC3

      Loosen the 2 nuts and remove the battery clamp.

    3. Remove the battery.

  9. REMOVE BATTERY TRAY


    1. Remove the battery tray.

  10. REMOVE BATTERY CARRIER (for LHD)

    A01VFJJ

    1. Disengage the 4 wire harness clamps and disconnect the wire harness from the battery carrier.

    2. Remove the 4 bolts and battery carrier.

  11. REMOVE BATTERY CARRIER (for RHD)

    A01VEJX

    1. Disengage the 5 wire harness clamps and disconnect the wire harness from the battery carrier.

    2. Remove the 4 bolts and battery carrier.

  12. REMOVE FAN AND GENERATOR V BELT

    Click here

  13. REMOVE GENERATOR ASSEMBLY

    Click here

  14. DISCONNECT COMPRESSOR ASSEMBLY WITH PULLEY


    1. Disconnect the compressor connector.

    2. A01VLN3

      Remove the 4 bolts and the separate the compressor assembly with pulley.

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  15. REMOVE EFI FUEL PIPE CLAMP

    A01VJ2H

    1. Remove the fuel pipe clamp.

  16. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    A01VDLX

    1. Disconnect the fuel tube Click here.

  17. SEPARATE NO. 1 FUEL VAPOR FEED HOSE

    A01VF33

    1. Disengage the No. 1 fuel vapor feed hose from the hose clamp.

    2. Disconnect the No. 1 fuel vapor feed hose from the duty vacuum switching valve.

  18. SEPARATE OUTLET HEATER WATER HOSE A

    A01VKI8

    1. Disconnect the outlet heater water hose from the air conditioning unit.

  19. DISCONNECT INLET HEATER WATER HOSE A

    A01VKEG

    1. Disconnect the inlet heater water hose from the air conditioning unit.

  20. DISCONNECT BOOSTER VACUUM TUBE


    1. A01VIY1

      Pinch the retainer as illustrated, then pull the booster vacuum tube connector out of the intake manifold.

      Text in Illustration
      A01VL3H Pinch
      A01VE7C Pull

    2. Disengage the clamp and disconnect the booster vacuum tube from the hose clamp.

  21. SEPARATE NO. 1 RADIATOR HOSE

    A01VHD9

    1. Disconnect the No. 1 radiator hose from the cylinder head.

  22. SEPARATE NO. 2 RADIATOR HOSE

    A01VFLG

    1. Disconnect the No. 2 radiator hose from the water inlet.

  23. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  24. SEPARATE TAIL EXHAUST PIPE ASSEMBLY

    A01VIVM

    1. Remove the 2 bolts and 2 compression springs and separate the tail exhaust pipe from the front exhaust pipe.

  25. SEPARATE NO. 2 HEATED OXYGEN SENSOR WIRE HARNESS

    A01VHVQ

    1. Disconnect the No. 2 heated oxygen sensor connector.

    2. A01VJQG

      Disengage the 3 clamps and disconnect the No. 2 heated oxygen sensor wire from the fan shroud.

  26. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  27. SEPARATE ENGINE WIRE


    1. A01VE4D

      Disconnect the 2 connectors from the positive (+) battery terminal.

    2. A01VH8O

      Disconnect the current sensor connector from the negative (-) battery terminal.

    3. A01VK16

      Slide the lever to disengage the lock, and separate the connector from the ECM.

    4. Remove the engine junction block cover.

    5. A01VFVW

      Disengage the wire harness clamp.

    6. Disconnect the connector from the engine junction block.

    7. A01VGZR

      Disengage the 2 claws and separate the wire harness from the junction block.

    8. A01VIPC

      Disengage the wire harness clamp.

    9. Remove the bolt and disconnect the ground wire from the transaxle.

    10. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.

  28. REMOVE RELEASE CYLINDER HEAT INSULATOR

    Click here

  29. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  30. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  31. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  32. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  33. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

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

    Click here

  35. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01VLHT

      Place wooden blocks or plate lift attachments in the positions as shown in the illustration and set an engine lifter underneath the crossmember.

      Text in Illustration
      A01VE0P Attachment Placement Positions

      Note


      • Place the wooden blocks or plate lift attachments so that the engine assembly with transaxle is level.

      • As the engine assembly with transaxle is very heavy, be sure to support it securely.

    2. A01VF3B

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

    3. A01VKU8

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

    4. A01VL1V

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

  36. INSTALL ENGINE HANGERS


    1. A01VJJ3

      Remove the bolt and separate the wire harness clamp bracket.

    2. A01VHSTE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers with the 2 bolts as shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Part Name Part No.
      No. 1 Engine Hanger 12281-40032
      No. 2 Engine Hanger 12282-40010
      Bolt 91671-80820

  37. FIX ENGINE ASSEMBLY WITH TRANSAXLE


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

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

      Note


      • Set the plate lift attachments so that the engine assembly with transaxle is level.

      • 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. A01VDM2

      Use a belt with a tighten mechanism or a rope to secure the engine assembly with transaxle to the engine lifter.

      Note


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

      • Set the engine assembly with transaxle so that it is horizontal.

  38. REMOVE ENGINE WIRE


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

  39. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  40. REMOVE STARTER ASSEMBLY

    Click here

  41. REMOVE ENGINE ASSEMBLY

    A01VGD7

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

  42. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  43. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  44. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  45. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A01VL9A

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator RH is necessary.


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

  46. REMOVE ENGINE MOUNTING INSULATOR LH

    A01VI73

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator LH is necessary.


    1. Remove the 3 bolts and engine mounting insulator LH.