ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

Some of these service operations affect the multi-mode manual transaxle system. Read the precautionary notices concerning the multi-mode manual transaxle system before servicing Click here.

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.

  • When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

  • After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester.

    (w/ DPF: Click here

    (w/o DPF: Click here

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. REMOVE REGARDING PARTS REMOVAL (for Multi-Mode Manual Transaxle)


    1. Before removing the clutch actuator or transaxle assembly from the vehicle, perform the Active Test to set the clutch actuator to the "Clamp" position Click here.

      Note

      If the actuator is not set to the "Clamp" position, the clutch fluid may be sprayed out.

      Tech Tips

      If the clutch actuator cannot be set to the "Clamp" position due to a malfunction (sticking, etc.), then the clutch fluid pressure should be released from the bleeder plug to prevent the fluid from spraying.

  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  5. REMOVE FRONT WHEELS

  6. REMOVE CENTER ENGINE UNDER COVER

  7. REMOVE ENGINE UNDER COVER RH

  8. REMOVE ENGINE UNDER COVER LH

  9. DRAIN ENGINE COOLANT

    Click here

  10. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  11. DRAIN MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)

    Click here

  12. REMOVE FRONT WIPER MOTOR AND LINK

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  19. REMOVE OUTER COWL TOP PANEL (for LHD)

    Click here

  20. REMOVE OUTER COWL TOP PANEL (for RHD)

    Click here

  21. REMOVE NO. 1 ENGINE COVER

    A01VG9NE01
    Text in Illustration
    *1 Pin
    *2 Hook
    *3 Bracket

    1. Raise the front of the No. 1 engine cover to detach the 2 pins. Then remove the 2 No. 1 engine cover hooks from the bracket, and remove the No. 1 engine cover.

  22. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    A01VEOUE02

    1. Disconnect the No. 4 water by-pass hose.

      Text in Illustration
      *1 No. 4 Water By-pass Hose
      *2 Water By-pass Hose Assembly

    2. Disengage the hose clamp and disconnect the water by-pass hose assembly.

    3. A01VK44

      Remove the bolt and reserve tank.

  23. REMOVE RADIATOR RESERVE TANK BRACKET

    A01VGP0

    1. Remove the bolt and radiator reserve tank bracket.

  24. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    A01VDY0

    1. Disconnect the mass air flow meter connector.

    2. Disengage the 4 wire harness clamps and separate the wire harness from the air cleaner cap.

    3. A01VHDV

      Unlock the 2 lock clamps and separate the air cleaner cap.

    4. Disconnect the fuel hose from the hose clamp.

    5. Disconnect the ventilation hose from the cylinder head cover.

    6. Disconnect the air cleaner hose from the turbocharger and remove the air cleaner cap with hose.

  25. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  26. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  27. REMOVE AIR CLEANER BRACKET

    A01VKHI

    1. Disengage the wire harness clamp.

    2. Remove the 3 bolts and the air cleaner bracket.

  28. REMOVE BATTERY


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

    2. A01VI0P

      Loosen the 2 nuts and remove the battery clamp.

    3. Remove the battery.

  29. REMOVE BATTERY TRAY


    1. Remove the battery tray.

  30. REMOVE BATTERY CARRIER (for LHD)

    A01VLPQ

    1. Disengage the 3 wire harness clamps and disconnect the wire harness from the battery carrier.

    2. Remove the 5 bolts and battery carrier.

  31. REMOVE BATTERY CARRIER (for RHD)

    A01VKBP

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

    2. Remove the 5 bolts and battery carrier.

  32. REMOVE FAN AND GENERATOR V BELT

    Click here

  33. DISCONNECT SUCTION HOSE (w/ Air Conditioning System)

    Click here

  34. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

    Click here

  35. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  36. DISCONNECT UNION TO CONNECTOR TUBE HOSE

    A01VHY9

    1. Disconnect the union to connector tube hose.

  37. DISCONNECT NO. 2 FUEL HOSE SUB-ASSEMBLY

    A01VJVB

    1. Disconnect the No. 2 fuel hose sub-assembly.

  38. DISCONNECT OUTLET HEATER WATER HOSE

    A01VIHZ

    1. Disconnect the outlet heater water hose.

  39. DISCONNECT INLET HEATER WATER HOSE

    A01VKO9

    1. Disconnect the inlet heater water hose.

  40. REMOVE NO. 2 AIR HOSE

    A01VE09

    1. Remove the No. 2 air hose.

  41. REMOVE NO. 1 RADIATOR HOSE


    1. A01VKEH

      Remove the No. 1 radiator hose.

  42. DISCONNECT NO. 2 RADIATOR HOSE

    A01VKY2

    1. Disconnect the No. 2 radiator hose.

  43. REMOVE NO. 3 AIR HOSE

    A01VDQ5

    1. Remove the No. 3 air hose.

  44. REMOVE NO. 1 AIR TUBE

    A01VJM9

    1. Remove the bolt and separate the wire harness.

    2. A01VEY1

      Loosen the hose clamp.

    3. Remove the 2 nuts and No. 1 air tube.

  45. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    Click here

  46. SEPARATE CLUTCH HOSE

    Click here

  47. REMOVE ENGINE WIRE

    A01VKU4

    1. Disconnect the 3 connectors from the positive (+) battery terminal.

    2. A01VJRL

      Disengage wire harness clamp and disconnect the current sensor connector and glow relay connector.

    3. A01VGEL

      Disengage the wire harness clamp and disconnect the ECM connector and wire harness clamp.

    4. Remove the engine junction block cover.

    5. A01VEU9

      Remove the bolt and separate the ground wire.

    6. Disengage the wire harness clamp.

    7. Disconnect the 2 connectors from the engine junction block.

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

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

  48. DISCONNECT TRANSAXLE WIRE (for Multi-Mode Manual Transaxle)


    1. A01VGVI

      Disconnect the 5 connectors and 2 clamps.

  49. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  50. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

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

    Click here

  52. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  53. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  55. REMOVE OIL PAN COVER

    Click here

  56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01VLM7

      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 front suspension crossmember sub-assembly is level.

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

      • To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.

    2. A01VH4H

      Remove the 2 bolts and engine mounting stay.

    3. A01VEL8

      Remove the bolt and 3 nuts and separate the engine mounting insulator RH.

    4. A01VG1G

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

    5. A01VDJW

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

  57. INSTALL ENGINE HANGER (w/ DPF)


    1. A01VIQCE05
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 Bolt
      *3 Tab
      *a Engine Rear

      Install the No. 1 engine hanger with a new bolt as shown in the illustration.

      Part Name Part No.
      No. 1 Engine Hanger 12281-33050
      Bolt 91552-81050
      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • Be sure to install the engine hanger with the tab contacting the rear side of the hole.

      • Be sure to use new bolts to install the engine hanger.

    2. A01VF6GE05
      Text in Illustration
      *1 No. 2 Engine Hanger
      *2 Bolt

      Install the No. 2 engine hanger with a new bolt as shown in the illustration.

      Part Name Part No.
      No. 2 Engine Hanger 12282-33050
      Bolt 91672-81025
      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      Note

      Be sure to use a new bolt to install the engine hanger.

    3. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

  58. INSTALL ENGINE HANGER (w/o DPF)


    1. A01VIQCE05
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 Bolt
      *3 Tab
      *a Engine Rear

      Install the No. 1 engine hanger with a new bolt as shown in the illustration.

      Part Name Part No.
      No. 1 Engine Hanger 12281-33050
      Bolt 91552-81050
      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • Be sure to install the engine hanger with the tab contacting the rear side of the hole.

      • Be sure to use new bolts to install the engine hanger.

    2. A01VHLRE01
      Text in Illustration
      *1 No. 2 Engine Hanger
      *2 Bolt

      Install the No. 2 engine hanger with a new bolt as shown in the illustration.

      Part Name Part No.
      No. 2 Engine Hanger 12282-33022
      Bolt 91672-81025
      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      Note

      Be sure to use a new bolt to install the engine hanger.

    3. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

  59. REMOVE WATER BY-PASS HOSE ASSEMBLY

    A01VKKH

    1. Remove the water by-pass hose assembly.

  60. REMOVE NO. 2 RADIATOR HOSE

    A01VIS2

    1. Remove the No. 2 radiator hose.

  61. REMOVE NO. 2 AIR TUBE ASSEMBLY

    A01VKXC

    1. Loosen the hose clamp.

    2. Remove the bolt and No. 2 air tube assembly.

  62. REMOVE STARTER ASSEMBLY

    Click here

  63. FIX 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.

      • To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.

    3. A01VISH

      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.

  64. REMOVE ENGINE ASSEMBLY

    A01VEVB

    1. Remove the 8 bolts and engine assembly from the manual transaxle.

  65. REMOVE BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)

    Click here

  66. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click here

  67. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  68. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  69. REMOVE CLUTCH TUBE BOOT (for Manual Transaxle)

  70. REMOVE CLUTCH TUBE BOOT (for Multi-Mode Manual Transaxle)

  71. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  72. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  73. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

    Click here

  74. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click here

  75. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  76. REMOVE CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  77. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

  78. REMOVE CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)

  79. REMOVE NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  80. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (w/ DPF)

    Click here

  81. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET (w/ DPF)

    Click here

  82. REMOVE NO. 3 MANIFOLD SUPPORT BRACKET (w/ DPF)

    Click here

  83. REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)

    Click here

  84. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  85. REMOVE DIFFERENTIAL PRESSURE SENSOR (w/ DPF)


    1. Remove the differential pressure sensor connector.

    2. A01VG5F

      Disconnect the 2 vacuum transmitting hoses.

    3. Remove the nut and differential pressure sensor.

  86. REMOVE NO. 1 TURBO INSULATOR (w/ DPF)

    Click here

  87. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)

    Click here

  88. REMOVE MANIFOLD SUPPORT BRACKET (w/ DPF)

    A01VDS2

    1. Remove the 3 bolts and manifold support bracket.

  89. REMOVE NO. 2 MANIFOLD SUPPORT BRACKET (w/ DPF)

    A01VGZ8

    1. Remove the 2 bolts and No. 2 manifold support bracket.

  90. REMOVE NO. 1 TURBO INSULATOR (w/o DPF)

    Click here

  91. REMOVE MANIFOLD SUPPORT BRACKET (w/o DPF)

    Click here

  92. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)

    Click here

  93. REMOVE TURBOCHARGER STAY

    Click here

  94. REMOVE MANIFOLD STAY

    Click here

  95. SEPARATE TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  96. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  97. REMOVE EXHAUST MANIFOLD

    Click here

  98. REMOVE CYLINDER BLOCK SIDE COVER

    A01VFJ7

    1. Remove the bolt, washer plate and the cylinder block side cover.

  99. REMOVE CRANKSHAFT POSITION SENSOR (w/ DPF)


    1. Disconnect the crankshaft position sensor connector.

    2. A01VKIG

      Disengage the crankshaft position sensor connector wire harness clamp from the wire harness bracket.

    3. Remove the 2 bolts and crankshaft position sensor.

  100. REMOVE CRANKSHAFT POSITION SENSOR (w/o DPF)

    Click here

  101. REMOVE FLYWHEEL SUB-ASSEMBLY

    A01VF7IE01

    1. Using SST, hold the crankshaft.

      SST
      09213-58014
      09330-00021
    2. A01VDRI

      Remove the 6 bolts and flywheel.

  102. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A01VIAR

    1. Remove the No. 1 crankshaft position sensor plate.

  103. DISCONNECT ENGINE WIRE

    A01VHC7E10
    Text in Illustration
    *a Engine side
    *b Transaxle side

    1. Disconnect the 2 ground bolts.

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

  104. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A01VHRB

    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.

  105. REMOVE ENGINE MOUNTING INSULATOR LH

    A01VFOM

    Tech Tips

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


    1. Remove the 5 bolts and engine mounting insulator LH.