ENGINE ASSEMBLY(w/o 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

  6. REMOVE ENGINE UNDER COVER RH

  7. REMOVE ENGINE UNDER COVER LH

  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

    B004591E02
    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.

  20. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    B00461IE02

    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. B0046JR

      Remove the bolt and reserve tank.

  21. REMOVE RADIATOR RESERVE TANK BRACKET

    B0047C2

    1. Remove the bolt and radiator reserve tank bracket.

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    B0047V9

    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. B0047YB

      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.

  23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  25. REMOVE AIR CLEANER BRACKET

    B00457X

    1. Disengage the wire harness clamp.

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

  26. REMOVE BATTERY


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

    2. B00483I

      Loosen the 2 nuts and remove the battery clamp.

    3. Remove the battery.

  27. REMOVE BATTERY TRAY


    1. Remove the battery tray.

  28. REMOVE BATTERY CARRIER (for LHD)

    B00484L

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

    2. Remove the 5 bolts and battery carrier.

  29. REMOVE BATTERY CARRIER (for RHD)

    B0046NI

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

    2. Remove the 5 bolts and battery carrier.

  30. REMOVE FAN AND GENERATOR V BELT

    Click here

  31. DISCONNECT 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. Disconnect the union to connector tube hose.

  35. DISCONNECT NO. 2 FUEL HOSE SUB-ASSEMBLY

    B0048B0

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

  36. DISCONNECT OUTLET HEATER WATER HOSE

    B0047LF

    1. Disconnect the outlet heater water hose.

  37. DISCONNECT INLET HEATER WATER HOSE

    B0046XI

    1. Disconnect the inlet heater water hose.

  38. REMOVE NO. 2 AIR HOSE

    B00457O

    1. Remove the No. 2 air hose.

  39. REMOVE NO. 1 RADIATOR HOSE


    1. B0046WJ

      Remove the No. 1 radiator hose.

  40. DISCONNECT NO. 2 RADIATOR HOSE

    B004861

    1. Disconnect the No. 2 radiator hose.

  41. REMOVE NO. 3 AIR HOSE

    B0046XL

    1. Remove the No. 3 air hose.

  42. REMOVE NO. 1 AIR TUBE

    B0046RI

    1. Remove the bolt and separate the wire harness.

    2. B0046Y1

      Loosen the hose clamp.

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

  43. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  44. SEPARATE CLUTCH HOSE

    Click here

  45. REMOVE ENGINE WIRE

    B0045JX

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

    2. B004698

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

    3. B0046KK

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

    4. Remove the engine junction block cover.

    5. B0046UY

      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.

  46. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  47. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

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

    Click here

  49. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  50. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  51. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  52. REMOVE OIL PAN COVER

    Click here

  53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B00486G

      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
      B0046KM 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. B0047V5

      Remove the 2 bolts and engine mounting stay.

    3. B00487S

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

    4. B00465F

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

    5. B004894

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

  54. INSTALL ENGINE HANGER


    1. B0046DXE08
      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. B0045EYE01
      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.

  55. REMOVE WATER BY-PASS HOSE ASSEMBLY

    B0046D6

    1. Remove the water by-pass hose assembly.

  56. REMOVE NO. 2 RADIATOR HOSE

    B0047UR

    1. Remove the No. 2 radiator hose.

  57. REMOVE NO. 2 AIR TUBE ASSEMBLY

    B00487H

    1. Loosen the hose clamp.

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

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

    Click here

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

    Click here

  60. 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. B0046L3

      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.

  61. REMOVE ENGINE ASSEMBLY

    B00473J

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

  62. REMOVE BLEEDER TO ACCUMULATOR TUBE

    Click here

  63. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  64. REMOVE CLUTCH TUBE BOOT

  65. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  66. REMOVE BLEEDER CLUTCH RELEASE TUBE

    Click here

  67. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  68. REMOVE CLUTCH DISC ASSEMBLY

  69. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  70. REMOVE NO. 1 TURBO INSULATOR

    Click here

  71. REMOVE MANIFOLD SUPPORT BRACKET

    Click here

  72. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  73. REMOVE TURBOCHARGER STAY

    Click here

  74. REMOVE MANIFOLD STAY

    Click here

  75. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  76. REMOVE EXHAUST MANIFOLD

    Click here

  77. REMOVE CYLINDER BLOCK SIDE COVER

    B00488L

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

  78. REMOVE CRANKSHAFT POSITION SENSOR

    Click here

  79. REMOVE FLYWHEEL SUB-ASSEMBLY

    B0047QME01

    1. Using SST, hold the crankshaft.

      SST
      09213-58014
      09330-00021
    2. B0045R8

      Remove the 6 bolts and flywheel.

  80. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    B004566

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

  81. DISCONNECT ENGINE WIRE

    B0045JNE13
    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.

  82. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    B0045YK

    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.

  83. 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.