ENGINE ASSEMBLY(w/ DPF) 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.

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

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE FRONT WHEELS

  5. REMOVE CENTER ENGINE UNDER COVER


    1. Remove the bolt, 2 clips, 7 screws and center engine under cover from the vehicle.

  6. REMOVE ENGINE UNDER COVER RH


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

  7. REMOVE ENGINE UNDER COVER LH


    1. Remove the 2 bolts and engine under cover LH from the vehicle.

  8. DRAIN ENGINE COOLANT

    Click here

  9. DRAIN MANUAL TRANSAXLE OIL

    Click here

  10. REMOVE FRONT WIPER MOTOR AND LINK

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  17. REMOVE OUTER COWL TOP PANEL (for LHD)

    Click here

  18. REMOVE OUTER COWL TOP PANEL (for RHD)

    Click here

  19. REMOVE NO. 1 ENGINE COVER

    B0047D7E01
    Text in Illustration
    *1 Pin
    *2 Grommet
    *3 No. 2 Engine Cover Bracket
    *a No. 1 Engine Cover Hook

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

  20. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    Click here

  21. REMOVE RADIATOR RESERVE TANK BRACKET

    B0047C2

    1. Remove the bolt and radiator reserve tank bracket from the engine mounting insulator sub-assembly RH.

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    B004815

    1. Disconnect the mass air flow meter connector.

    2. Disengage the 4 clamps to disconnect the wire harness from the air cleaner cap.

    3. B0045Z4

      Disengage the 2 clamps and 2 guides to separate the air cleaner cap from the air cleaner case sub-assembly.

    4. Disconnect the fuel hose clamp from the air cleaner hose.

    5. Slide the hose clip and disconnect the ventilation hose from the cylinder head cover sub-assembly.

    6. Loosen the hose clamp and disconnect the No. 1 air cleaner hose from the compressor inlet elbow sub-assembly.

  23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  25. REMOVE AIR CLEANER BRACKET

    B00472T

    1. Remove the 3 bolts and air cleaner bracket from the vehicle.

  26. REMOVE BATTERY


    1. B0045G8E02

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

    2. Loosen the nut A.

    3. Remove the nut and battery clamp from the battery carrier.

    4. Remove the battery from the battery tray.

  27. REMOVE BATTERY TRAY


    1. B0045EJ

      Remove the battery tray from the battery carrier.

  28. REMOVE BATTERY CARRIER (for LHD)

    B0047RQ

    1. Disengage the 3 clamps to disconnect the engine wire from the battery carrier.

    2. Remove the 5 bolts and battery carrier from the engine mounting insulator and vehicle.

  29. REMOVE BATTERY CARRIER (for RHD)

    B00487V

    1. Disengage the 4 clamps to disconnect the engine wire from the battery carrier.

    2. Remove the 5 bolts and battery carrier from the engine mounting insulator and vehicle.

  30. REMOVE FAN AND GENERATOR V BELT

    Click here

  31. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)

    Click here

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

    Click here

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

    Click here

  34. DISCONNECT UNION TO CONNECTOR TUBE HOSE

    B00460Z

    1. Slide the hose clip and disconnect the union to connector tube hose from the vacuum pump assembly.

  35. DISCONNECT NO. 1 FUEL HOSE SUB-ASSEMBLY

    Click here

  36. DISCONNECT INLET HEATER WATER HOSE

    B004660

    1. Slide the hose clip and disconnect the inlet heater water hose from the water by-pass pipe sub-assembly.

  37. DISCONNECT OUTLET HEATER WATER HOSE

    B0047QL

    1. Slide the hose clip and disconnect the outlet heater water hose from the water by-pass pipe sub-assembly.

  38. REMOVE NO. 2 AIR HOSE

    B0045O9

    1. Loosen the 2 hose clamps and remove the No. 2 air hose from the No. 1 air tube and intercooler assembly.

  39. REMOVE NO. 1 RADIATOR HOSE


    1. B0047BB

      Slide the 2 hose clips and remove the No. 1 radiator hose from the water outlet sub-assembly and radiator assembly.

  40. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  41. REMOVE NO. 3 AIR HOSE

    B0046XL

    1. Loosen the 2 hose clamps and remove the No. 3 air hose from the No. 2 air tube assembly and intercooler assembly.

  42. REMOVE NO. 1 AIR TUBE

    B0047LZ

    1. Remove the bolt and nut and separate the engine wire from the No. 1 air tube.

    2. B0047I3

      Loosen the hose clamp and disconnect the No. 1 air hose from the turbocharger sub-assembly.

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

  43. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  44. SEPARATE CLUTCH HOSE

    Click here

  45. DISCONNECT ENGINE WIRE (for LHD)

    B00485S

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

    2. B0047TA

      Disconnect the current sensor connector.

    3. Disengage the clamp and disconnect the engine wire from the bracket.

    4. B0045SQ

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

    5. Pull up the lever to loosen the lock and disconnect the connector from the ECM.

      Note

      If there are is any foreign matter such as mud or water on a connector, clean the connector.

    6. Remove the relay block cover.

    7. B0046UY

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

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

    9. Disconnect the 2 connectors from the engine room junction block.

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

  46. DISCONNECT ENGINE WIRE (for RHD)

    B00485S

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

    2. B0047TA

      Disconnect the current sensor connector.

    3. Disengage the clamp and disconnect the engine wire from the bracket.

    4. B0045XI

      Pull up the lever to loosen the lock and disconnect the connector from the ECM.

      Note

      If there are is any foreign matter such as mud or water on a connector, clean the connector.

    5. Remove the relay block cover.

    6. B0046UY

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

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

    8. Disconnect the 2 connectors from the engine room junction block.

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

  47. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  48. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

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

    Click here

  50. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  51. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  53. REMOVE OIL PAN COVER


    1. B0045CE

      Remove the 2 bolts, 2 plate washers and oil pan cover from the oil pan sub-assembly.

  54. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B0046YN

      Loosen the bolt of the engine moving control rod.

    2. B00486G

      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 and front suspension crossmember sub-assembly.

      Text in Illustration
      B0046KM Attachment Placement Positions

      Note


      • Place the height adjustment and 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.

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

    3. B0046OR

      Remove the 2 bolts and engine mounting stay from the engine mounting insulator sub-assembly and engine mounting bracket RH.

    4. B0045ZX

      Remove the bolt and 3 nuts to separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    5. B00465F

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

      Tech Tips

      Loosen by holding the nut and turning the through bolt.

    6. B004894

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

      Note

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

  55. REMOVE NO. 5 CONVERTER SUPPORT BRACKET

    Click here

  56. INSTALL ENGINE HANGER


    1. B0045Z0E02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 Bolt
      *a Tab
      *b Hole

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

      Part Name Part No.
      No. 1 Engine Hanger 12281-33080
      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. B0047QCE02
      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 12282-00N10
      Bolt 91672-81025 or 90119-W0026
      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.

  57. REMOVE WATER BY-PASS HOSE ASSEMBLY

    B0046D6

    1. Slide the hose clip and remove the water by-pass hose assembly from the water inlet.

  58. REMOVE NO. 2 RADIATOR HOSE

    B0046IO

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

  59. REMOVE NO. 2 AIR TUBE ASSEMBLY

    B00487H

    1. Loosen the hose clamp.

    2. Remove the bolt and No. 2 air tube assembly from the diesel throttle body assembly and cylinder block sub-assembly.

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

    Click here

  61. REMOVE STARTER ASSEMBLY (w/o Stop and Start System for Cold Area Specification Vehicles)

    Click here

  62. REMOVE STARTER ASSEMBLY (w/o Stop and Start System except Cold Area Specification Vehicles)

    Click here

  63. REMOVE ENGINE WIRE

    B0046QM

    1. Remove the 4 bolts to disconnect the engine wire from the engine assembly and manual transaxle assembly.

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

  64. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B0045NK

      Remove the bolt and front suspension crossmember sub-assembly from the engine moving control rod bracket.

  65. 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 height adjustment or plate lift attachments and set them in place.

      Note


      • Place the height adjustment and 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.

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

    3. B0045H3

      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.

  66. REMOVE ENGINE ASSEMBLY

    B00473J

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

  67. REMOVE BLEEDER TO ACCUMULATOR TUBE

    Click here

  68. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  69. REMOVE CLUTCH TUBE BOOT

  70. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  71. REMOVE BLEEDER CLUTCH RELEASE TUBE

    Click here

  72. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  73. REMOVE CLUTCH DISC ASSEMBLY

  74. REMOVE NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  75. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  76. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  77. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  78. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B0047WV

      Remove the wiring harness clamp bracket from the cylinder head cover sub-assembly.

  79. REMOVE SENSOR BRACKET

    Click here

  80. REMOVE TURBO INSULATOR

    Click here

  81. REMOVE NO. 2 PIPE

    Click here

  82. REMOVE NO. 4 CONVERTER SUPPORT BRACKET

    Click here

  83. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  84. REMOVE EXHAUST MANIFOLD


    1. B0046M6

      Disconnect the camshaft position sensor connector.

    2. Disconnect the exhaust gas temperature sensor connector.

    3. Remove the bolt and wiring harness clamp bracket from the timing chain cover assembly.

    4. Disengage the claw to disconnect the exhaust gas temperature sensor wire connector from the wiring harness clamp bracket.

    5. Disengage the clamp to disconnect the exhaust gas temperature sensor wire from the wiring harness clamp bracket.

    6. Remove the 4 bolts, 3 nuts and exhaust manifold from the turbocharger sub-assembly, No. 1 converter support bracket, manifold stay and No. 2 converter support bracket.

      B0046LV
    7. B0046SC

      Remove the gasket from the turbocharger sub-assembly.

  85. REMOVE MANIFOLD SUPPORT BRACKET

    B0045MC

    1. Remove the 3 bolts and manifold support bracket from the cylinder block sub-assembly.

  86. DISCONNECT NO. 1 TURBO WATER HOSE

    Click here

  87. DISCONNECT NO. 2 TURBO WATER HOSE

    Click here

  88. REMOVE TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  89. REMOVE TURBOCHARGER STAY

    Click here

  90. REMOVE MANIFOLD STAY

    Click here

  91. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  92. REMOVE EXHAUST MANIFOLD

    Click here

  93. REMOVE CYLINDER BLOCK SIDE COVER

    B0045NU

    1. Remove the bolt, plate washer and cylinder block side cover from the cylinder block sub-assembly.

  94. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  95. REMOVE FLYWHEEL SUB-ASSEMBLY

    B0047QME01

    1. Using SST, hold the crankshaft damper sub-assembly.

      SST
      09213-58014
      09330-00021
    2. B0045R8

      Remove the 6 bolts and flywheel sub-assembly from the crankshaft.

  96. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    B004566

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

  97. 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.

  98. REMOVE ENGINE HANGER


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

  99. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    B00485H

    Tech Tips

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


    1. Remove the 3 bolts and engine mounting insulator sub-assembly RH from the vehicle.

  100. REMOVE ENGINE MOUNTING INSULATOR LH

    B00485U

    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 from the vehicle.