ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

Note

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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE FRONT WHEEL

  5. REMOVE ENGINE UNDER COVER LH


    1. Remove the 3 bolts, 3 screws and engine under cover LH from the vehicle.

  6. REMOVE ENGINE UNDER COVER RH


    1. Remove the 2 bolts, screw and engine under cover RH from the vehicle.

  7. DRAIN ENGINE COOLANT

    Click here

  8. DRAIN MANUAL TRANSAXLE OIL

    Click here

  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK

    Click here

  10. REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)

    Click here

  11. REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)

    Click here

  12. REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)

    Click here

  13. REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)

    Click here

  14. REMOVE INNER COWL TOP TO COWL BRACE (for LHD)

    Click here

  15. REMOVE INNER COWL TOP TO COWL BRACE (for RHD)

    Click here

  16. REMOVE OUTER COWL TOP PANEL (for LHD)

    Click here

  17. REMOVE OUTER COWL TOP PANEL (for RHD)

    Click here

  18. REMOVE BATTERY


    1. Open the positive (+) battery terminal cover.

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

    3. B004700E02

      Loosen the nut A.

    4. Remove the nut B and battery clamp sub-assembly from the battery carrier.

    5. B00478O

      Remove the battery from the battery tray.

  19. REMOVE BATTERY TRAY

    B0047QG

    1. Remove the battery tray from the battery carrier.

  20. SEPARATE BATTERY CARRIER

    B0045GG

    1. Disengage the 5 clamps to disconnect the engine wire from the battery carrier.

    2. B00488P

      Remove the 4 bolts and battery carrier from the vehicle.

  21. REMOVE INLET NO. 1 AIR CLEANER

    Click here

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  24. REMOVE FAN AND GENERATOR V BELT

    Click here

  25. REMOVE GENERATOR ASSEMBLY (for DENSO Made)

    Click here

  26. REMOVE GENERATOR ASSEMBLY (for VALEO Made)

    Click here

  27. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)


    1. B0045DD

      Disconnect the compressor assembly with pulley connector.

    2. Remove the 4 bolts to separate the compressor assembly with pulley from the cylinder block sub-assembly and oil pan sub-assembly.

      Tech Tips

      It is not necessary to completely remove the compressor assembly with pulley. With the No. 1 cooler refrigerant discharge hose suction hose sub-assembly connected to the compressor, hang the compressor on the vehicle body with a rope.

  28. REMOVE EFI FUEL PIPE CLAMP

    B0047UN

    Note

    Before disconnecting the fuel tube connector, make sure there are no deposits, clean them away.


    1. Remove the EFI fuel pipe clamp from the fuel tube sub-assembly and fuel tube.

  29. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    B0047XME03
    Text in Illustration
    *1 Retainer
    *2 Nylon Tube
    *3 Pipe
    *4 O-ring
    *5 Fuel Tube Connector
    B0046MU Pinch
    B0045SR Pull

    1. Disconnect the fuel tube sub-assembly from the fuel tube.


      1. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it.

      3. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      4. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel tube connector and fuel pipe with plastic bags to prevent damage and contamination.

  30. SEPARATE NO. 1 FUEL VAPOR FEED HOSE

    B0047W8

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

    2. Slide the hose clip and disconnect the No. 1 fuel vapor feed hose from the duty vacuum switching valve.

  31. SEPARATE OUTLET HEATER WATER HOSE A

    B0047O3

    1. Slide the hose clip and disconnect the outlet heater water hose A from the heater unit.

  32. DISCONNECT INLET HEATER WATER HOSE A

    B0047F8

    1. Slide the hose clip and disconnect the inlet heater water hose A from the heater unit.

  33. DISCONNECT VACUUM HOSE ASSEMBLY

    Click here

  34. SEPARATE NO. 1 RADIATOR HOSE

    B0046EK

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

  35. SEPARATE NO. 2 RADIATOR HOSE

    B0045H6

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

  36. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY


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

    2. B0045RS

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

    3. B00479H

      Remove the 2 bolts, 2 compression spring to separate the front exhaust pipe assembly from the tail exhaust pipe assembly.

    4. Remove the 2 bolts, 2 compression spring to separate the front exhaust pipe assembly from the exhaust manifold.

    5. Disconnect the 3 exhaust pipe supports to remove the front exhaust pipe assembly from the vehicle.

    6. Remove the exhaust pipe gasket from the exhaust manifold.

    7. Remove the No. 2 exhaust pipe gasket from the front exhaust pipe assembly.

  38. DISCONNECT ENGINE WIRE


    1. B004793E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Raise the lever while pushing the lock on the lever to disconnect the ECM connector.

    2. for LHD:


      1. Disengage the clamp to disconnect the engine wire from the wire harness clamp bracket.

    3. Remove the engine room relay block cover.

    4. B0046UR

      Disengage the clamp to disconnect the engine wire from the vehicle.

    5. Disconnect the connector from the engine room relay block.

    6. Disengage the 2 claws to disconnect the engine wire from the engine room block.

    7. B0046OI

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

    8. B0045V7

      Remove the bolt to disconnect the engine wire from the transaxle.

    9. Disengage the 2 clamps to disconnect the engine wire from the transaxle.

    10. B0048CI

      w/ Stop and Start System:


      1. Disconnect the neutral position switch connector.

      2. Disengage the 2 clamps to disconnect the engine wire from the wire harness clamp bracket.

      3. Remove the bolt and wire harness clamp bracket from the clutch flexible hose bracket.

  39. REMOVE RELEASE CYLINDER HEAT INSULATOR

    Click here

  40. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  41. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  42. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  43. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  44. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  45. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

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

    Click here

  47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B00465R

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

      Text in Illustration
      B0046KM Attachment Placement Position

      Note


      • Place the height adjustment or 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.

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

    2. B0045RF

      Remove the bolt and 2 nuts to separate the engine mounting insulator sub-assembly RH from the timing chain cover sub-assembly.

    3. B0046ZT

      Remove the bolt, through bolt, nut to separate the engine mounting insulator LH from the engine mounting bracket LH.

      Tech Tips

      Loosen by holding the nut and turning the through bolt.

    4. B0047YF

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

      Note

      When removing the engine assembly with transaxle, be careful not to damage any wire harnesses or the steering shaft.

  48. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B0046UO

      Disengage the clamp to disconnect the engine wire from the wire harness clamp bracket.

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

  49. INSTALL ENGINE HANGER


    1. B0047NUE02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Tech Tips

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

  50. FIX ENGINE ASSEMBLY WITH TRANSAXLE


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

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

      Note


      • Set the height adjustment or 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. B0045BK

      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.

  51. REMOVE ENGINE WIRE


    1. B0047L2

      Remove the bolt to disconnect the engine wire from the cylinder head sub-assembly.

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

  52. REMOVE FLYWHEEL HOUSING SIDE COVER (w/ Stop And Start System)

    Click here

  53. REMOVE FLYWHEEL HOUSING SIDE COVER (for Cold Area Specification Vehicles)

    Click here

  54. REMOVE FLYWHEEL HOUSING SIDE COVER (except Cold Area Specification Vehicles)

    Click here

  55. REMOVE STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  56. REMOVE STARTER ASSEMBLY (for Cold Area Specification Vehicles)

    Click here

  57. REMOVE STARTER ASSEMBLY (except Cold Area Specification Vehicles)

    Click here

  58. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  59. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  60. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  61. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  62. INSTALL 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.

  63. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    B0045BD

    Tech Tips

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


    1. Remove the 3 bolts.

    2. Disengage the hook to remove the engine mounting insulator sub-assembly RH from the vehicle.

  64. REMOVE ENGINE MOUNTING INSULATOR LH

    B0046MA

    Tech Tips

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


    1. Remove the 3 bolts.

    2. Disengage the hook to remove the engine mounting insulator LH from the vehicle.

  65. REMOVE ENGINE HANGER


    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly.