ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

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  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  6. REMOVE FRONT WHEELS

  7. REMOVE ENGINE UNDER COVER LH


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

  8. REMOVE ENGINE UNDER COVER RH


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

  9. DRAIN ENGINE COOLANT

    Click here

  10. DRAIN SUPERCHARGER COOLANT

    Click here

  11. DRAIN ENGINE OIL

    Click here

  12. DRAIN MANUAL TRANSAXLE OIL

    Click here

  13. REMOVE WINDSHIELD WIPER LINK ASSEMBLY

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  14. REMOVE FRONT NO. 1 VENTILATOR SEAL


  15. REMOVE FRONT AIR SHUTTER SEAL RH


  16. REMOVE INNER COWL TOP TO COWL BRACE


  17. REMOVE OUTER COWL TOP PANEL


  18. REMOVE FRONT SUSPENSION UPPER CENTER BRACE SUB-ASSEMBLY


    1. B0046S6

      Remove the 4 nuts and front suspension upper center brace sub-assembly from the front suspension upper brace bracket LH and RH.

  19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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  20. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. B0047DV

      Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B0047Z4

      Disconnect the wire harness clamp from the air cleaner case sub-assembly.

    2. Remove the 2 bolts and air cleaner case sub-assembly.

  22. REMOVE BATTERY


    1. B004640

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

    2. Remove the 2 nut and battery clamp sub-assembly.

    3. B00466C

      Remove the battery.

  23. REMOVE BATTERY TRAY


    1. B0047TD

      Remove the battery tray.

  24. REMOVE BATTERY CARRIER


    1. B0047UY

      Disconnect the 6 wire harness clamps from the battery carrier.

    2. Remove the 5 bolts and battery carrier.

  25. DISCONNECT WIRE HARNESS


    1. B00470R

      Disconnect the clamp and wire harness from the air cleaner blacket.

    2. B00460N

      Pull up the lever to disconnect the ECM connector.

    3. Disconnect the wire harness clamp.

    4. Remove the No. 1 engine room relay block cover from the engine room relay block and junction block assembly.

    5. B0047NR

      Disconnect the wire harness clamp.

    6. Disconnect the 2 wire harness connectors and wire harness from the engine room relay block and junction block assembly.

    7. B00457Z

      Disengage the 2 claws and wire harness from the engine room relay block and junction block assembly.

    8. B0046OI

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

    9. B0046YK

      Remove the bolt and disconnect the 2 wire harness clamp from the manual transaxle assembly.

    10. Disconnect all the wire harnesses and connectors.

  26. REMOVE FAN AND GENERATOR V BELT

    Click here

  27. DISCONNECT NO. 3 RADIATOR HOSE


    1. B0046N6

      Slide the clip and disconnect the No. 3 radiator hose from the cylinder head sub-assembly.

  28. DISCONNECT NO. 4 SUB-RADIATOR HOSE

    Click here

  29. DISCONNECT NO. 7 SUB-RADIATOR HOSE

    Click here

  30. DISCONNECT RESERVE TANK INLET HOSE


    1. B0048AO

      Slide the hose clip and disconnect the reserve tank inlet hose from the intercooler reserve tank assembly.

  31. DISCONNECT RESERVE TANK OUTLET HOSE

    Click here

  32. DISCONNECT RADIATOR HOSE


    1. B0048BH

      Slide the clip and disconnect the radiator hose from the water inlet.

  33. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  34. REMOVE NO. 1 FUEL VAPOR FEED HOSE


    1. B00479C

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

  35. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. B0045UA

      Slide the clip and disconnect the union to check valve hose from the air tube.

  36. DISCONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. B0045Q9

      Slide the clip and disconnect the union to check valve hose from the air tube.

  37. DISCONNECT OUTLET HEATER WATER HOSE


    1. B0046ZR

      Slide the clip and disconnect the outlet heater water hose from the air conditioner unit assembly.

  38. DISCONNECT INLET HEATER WATER HOSE


    1. B0046I2

      Slide the clip and disconnect the inlet heater water hose from the air conditioner unit assembly.

  39. SEPARATE CLUTCH HOSE

    Click here

  40. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY

    Click here

  41. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  42. REMOVE REAR CONSOLE BOX ASSEMBLY

    Click here

  43. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  45. REMOVE DRIVE SHAFT ASSEMBLY

    Click here

  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 SUSPENSION MEMBER BRACE SUB-ASSEMBLY

    Click here

  50. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set an engine lifter.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.

      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

    2. B0047AV

      Remove the 2 bolts and engine mounting stay.

    3. Remove the 5 bolt, 2 nuts and separate the engine mounting insulator sub-assembly RH.

    4. B0045QP

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

      Tech Tips

      When removing the through bolt, keep the nut from rotating.

    5. B00468X

      Remove the 4 bolt.

    6. Carefully remove the engine assembly with transaxle from the vehicle.

      Note

      Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

  51. REMOVE WIRE HARNESS CLAMP BRACKET

    B004826

    1. Disengage the 2 clamps.

    2. Remove the bolt and wire harness clamp bracket.

  52. INSTALL ENGINE HANGER


    1. B00487T

      Install the engine hanger with the bolt.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

      Tech Tips

      Engine Hanger 12282-37011
      Bolt 91552-81050

    2. Attach an engine sling device and hang the engine assembly with transaxle with a chain block.

      Note


      • Pay attention to the angle of the sling device as the engine assembly with transaxle or alternator tensioner bracket and engine hanger may be damaged or deformed if the angle is incorrect.

      • 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.

  53. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly with transaxle.

  54. REMOVE STARTER ASSEMBLY

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  55. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. B0045OM

      Remove the flywheel housing side cover from the cylinder block sub-assembly.

  56. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  57. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  58. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  59. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  60. INSTALL ENGINE ASSEMBLY TO 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.

  61. REMOVE ENGINE HANGER


    1. Remove the bolt and No. 2 engine hanger.

  62. REMOVE GENERATOR ASSEMBLY

    Click here

  63. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.


    1. B0048AM

      Remove the 5 bolts.

    2. Disengage the hook and engine mounting insulator LH.