ENGINE ASSEMBLY REMOVAL


  1. PRECAUTION

    CAUTION:

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

    Note

    After turning the ignition 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


    1. Turn the A/C switch on.

    2. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.

    3. Turn the ignition switch off.

    4. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  5. SECURE STEERING WHEEL

  6. REMOVE FRONT WHEELS

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

  9. REMOVE ENGINE UNDER COVER LH

  10. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

  11. REMOVE ENGINE UNDER COVER RH

  12. REMOVE FRONT FENDER APRON SEAL LH

  13. REMOVE FRONT FENDER APRON SEAL RH

  14. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

    3. Clean the oil pan drain plug and install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  15. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap sub-assembly.

      A01HP2DE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Radiator Drain Cock Plug

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

  16. DRAIN AUTOMATIC TRANSAXLE FLUID


    1. Remove the front wheel opening extension pad LH, engine under cover LH and front fender apron seal LH.

    2. A01HOOP

      Remove the refill plug and gasket from the automatic transaxle assembly.

    3. A01HOF0E03
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube
      *2 Overflow Plug
      *3 Hexagon Socket Wrench

      Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transaxle assembly.

    4. A01HOCHE04
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube
      *2 Hexagon Socket Wrench
      *a Overflow Plug Hole

      Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle assembly.

    5. Drain automatic transaxle fluid from the automatic transaxle assembly.

    6. A01HOCHE04
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube
      *2 Hexagon Socket Wrench
      *a Overflow Plug Hole

      Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle assembly.

      Torque:
      0.8 N*m  { 8 kgf*cm, 7 in.*lbf }
    7. A01HOF0E03
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube
      *2 Overflow Plug
      *3 Hexagon Socket Wrench

      Using a 6 mm hexagon socket wrench, install a new gasket and the overflow plug to the automatic transaxle assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 29 ft.*lbf }
    8. A01HOOP

      Install a new gasket and the refill plug to the automatic transaxle assembly.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  17. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01HOR8

      Remove the 7 clips and cool air intake duct seal.

  18. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01HQOT

      Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the engine cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

  19. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A01HN8W

      Remove the 2 bolts and inlet air cleaner assembly.

  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01HQTS

      Disconnect the vacuum switching valve assembly from the air cleaner hose.

    2. A01HMBU

      Disconnect the mass air flow meter connector and 2 wire harness clamps from the air cleaner cap sub-assembly.

    3. A01HR4F

      Separate the fuel vapor feed hose from the air cleaner hose.

    4. A01HOYC

      Disconnect the ventilation hose from the cylinder head cover.

    5. A01HO8A

      Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.

    6. A01HP5O

      Release the 2 clamps and remove the air cleaner cap sub-assembly.

  21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly.

  22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01HPCW

      Disconnect the wire harness clamp.

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

  23. REMOVE BATTERY


    1. A01HMWM

      Loosen the nut, and separate the positive (+) battery terminal.

    2. Loosen the nut, and remove the bolt and battery clamp.

    3. Remove the battery and battery tray.

  24. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01HQ5C

      Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.

    2. Disconnect the No. 1 radiator hose.

  25. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01HO7H

      Disconnect the No. 2 radiator hose.

  26. DISCONNECT INLET HEATER WATER HOSE


    1. A01HOVJ

      Disconnect the inlet heater water hose.

  27. DISCONNECT OUTLET HEATER WATER HOSE


    1. A01HOZD

      Disconnect the 3 outlet heater water hoses.

  28. REMOVE STARTER ASSEMBLY


    1. A01HPCJ

      Disconnect the starter connector.

    2. Open the terminal cap, remove the nut and disconnect the starter wire.

    3. A01HQ6M

      Remove the 2 bolts and starter.

  29. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. A01HPQN

      Remove the 2 nuts and disconnect the wire clamp.

    3. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

    4. A01HQ1R

      Disconnect the 4 connectors.

    5. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

    6. A01HNTE

      Pull up the lever to disconnect the ECM connector.

    7. Disconnect the 2 wire clamps.

  30. DISCONNECT NO. 1 AIR CLEANER BRACKET


    1. A01HNSY

      Disconnect the 2 wire clamps.

    2. Remove the bolt and No. 1 air cleaner bracket.

  31. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01HMFG

      Remove the nut and disconnect the transmission control cable from the control shaft lever.

    2. A01HPMC

      Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.

  32. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01HNVV

      Remove the 2 bolts and No. 2 engine mounting stay RH.

  33. SEPARATE EARTH WIRE


    1. A01HQAH

      Remove the bolt and separate the earth wire from the engine moving control rod bracket.

  34. REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. A01HP5E

      Remove the 4 bolts and engine moving control rod bracket.

  35. REMOVE ENGINE MOVING CONTROL ROD


    1. A01HQM3

      Remove the bolt, No. 3 engine mounting stay RH and engine moving control rod from the engine moving control rod bracket.

      Tech Tips

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  36. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A01HOT4

      Disconnect the union to connector tube hose.

  37. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01HPIU

      Remove the bolt.

    2. Disconnect the 2 connectors.

    3. A01HO4E

      Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor assembly with pulley.

    4. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  38. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made)


    1. A01HMBX

      Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.

    2. Remove the O-ring from the suction hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  39. DISCONNECT NO.1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made)


    1. A01HMBX

      Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor assembly with pulley.

    2. Remove the O-ring from the No. 1 cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  40. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01HO7D

      Release the claw and remove the No. 1 fuel pipe clamp.

    2. Pinch the fuel tube connector and then pull out the fuel main tube.

      Note


      • Check for dirt and foreign matter on the pipe and around the connector. Clean if necessary and then disconnect the connector.

      • Disconnect the connector by hand.

      • Do not bend, fold or rotate the nylon tube.

      • If the pipe and connector are stuck together, push and pull the connector until it becomes free.

      • Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

  41. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01HQ42

      Remove the 2 bolts, 2 compression springs.

    2. Remove the front exhaust pipe assembly from the exhaust pipe support.

    3. Remove the gasket from the exhaust manifold converter sub-assembly.

  42. REMOVE FRONT AXLE SHAFT NUT LH


    1. A01HPLVE01

      Using SST and a hammer, release the staked part of the front axle shaft nut.

      SST
      09930-00010

      Note

      Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle shaft nut.

  43. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  44. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


    1. A01HP89

      Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.

      If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

  45. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  46. SEPARATE FRONT SPEED SENSOR LH


    1. A01HR45

      Remove the bolt, disengage the clamp and separate the front speed sensor and front flexible hose.

      Note

      Be sure to separate the front speed sensor from the front shock absorber completely.

    2. A01HOU5

      Remove the bolt and front speed sensor from the steering knuckle.

      Note


      • Prevent foreign matter from contacting the sensor tip.

      • Be careful not to damage the front speed sensor.

      • Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.

  47. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  48. SEPARATE TIE ROD ASSEMBLY LH


    1. A01HQC1

      Remove the cotter pin and nut.

    2. A01HNSME01

      Install SST to the tie rod assembly LH.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure that the lower ends of the tie rod assembly LH and SST are aligned.

    3. Secure SST using a string.

      Note

      Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.

    4. Using SST, separate the tie rod assembly LH from the steering knuckle.

      A01HPWBE02
      Text in Illustration
      *1 Center Nut - -
      *a String *b Grease Application Area
      A01HQYC Place the wrench here. - -
      SST
      09960-20010   ( 09961-02010 )

      CAUTION:

      Apply grease to the bolt threads and the tip of SST.

      Note


      • Install SST with the center nut so that A and B shown in the illustration are parallel. Otherwise, the dust cover may be damaged.


      • Be sure to place the wrench on the part indicated in the illustration.


      • Do not damage the front disc brake dust cover.


      • Do not damage the ball joint dust cover.


      • Do not damage the steering knuckle.

  49. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  50. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH


    1. A01HOGG

      Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.

  51. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  52. SEPARATE FRONT AXLE ASSEMBLY LH


    1. A01HOONE01
      Text in Illustration
      *a Matchmark

      Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.

    2. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.

      If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer.

  53. SEPARATE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  54. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01HQD7E02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the steering intermediate shaft assembly and steering link assembly.

    2. Remove the bolt.

    3. Separate the steering intermediate shaft assembly from the steering link assembly.

  55. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A01HNLF

      Remove the flywheel housing under cover.

  56. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A01HMMQ

      Turn the crankshaft to gain access to the removal locations of the 6 torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

  57. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01HQOS

      Set the engine lifter.

      Text in Illustration
      A01HOFH Attachment Installation Position

      Note


      • Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

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

      • 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.

      • 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 or removed from an engine stand.

    2. A01HPU3

      Remove the 4 bolts, 2 nuts, and frame side rail plate RH and LH.

    3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.

    4. Operate the engine lifter and remove the engine assembly from the vehicle.

      Note


      • Make sure that the engine is clear of all wiring and hoses.

      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.

    5. Install engine hangers Click here.

  58. REMOVE ENGINE WIRE


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

  59. REMOVE V-RIBBED BELT


    1. A01HMJ6

      Attach a wrench to the hexagonal portion of the belt tensioner as shown in the illustration, rotate the belt tensioner clockwise, and remove the V-ribbed belt.

  60. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY


    1. A01HMEH

      Remove the 2 bolts and 2 nuts.

    2. A01HQA2

      Using an E8 "TORX" socket, remove the 2 stud bolts and compressor assembly with pulley.

      Tech Tips

      Leave the 2 stud bolts in the vehicle with the remaining in the compressor assembly with pulley.

  61. REMOVE GENERATOR ASSEMBLY


    1. A01HQBK

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the generator wire.

    4. Remove the bolt and wire harness clamp bracket.

    5. A01HN50

      Remove the 2 bolts and generator.

  62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01HOSEE01

      Using SST, remove the front drive shaft assembly LH.

      SST
      09520-00031
      09520-01010

      Note


      • Do not damage the transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • Do not drop the front drive shaft assembly LH.

  63. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. A01HQ3B

      Using a screwdriver, remove the front drive shaft hole snap ring LH.

  64. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A01HPR8

      Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

    2. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.

      Note


      • Do not damage the front transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • Do not drop the front drive shaft assembly RH.

    3. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH.

  65. REMOVE FRONT FRAME ASSEMBLY


    1. A01HOM8

      Remove the nut and separate the engine mounting insulator LH.

    2. A01HO88

      Remove the bolt and separate the front engine mounting insulator.

    3. A01HO7X

      Remove the nut and separate the engine mounting insulator RH.

    4. Remove the front frame assembly.

    5. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface.

      Note


      • Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally.

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

      • Using an engine sling device and engine lift, secure the engine assembly before service.

  66. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01HMQC

      Remove the 3 nuts and front engine mounting insulator.

      Tech Tips

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

  67. REMOVE ENGINE MOUNTING INSULATOR LH


    1. A01HOLI

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 3 nuts and engine mounting insulator LH.

      Tech Tips

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

  68. REMOVE ENGINE MOUNTING INSULATOR RH


    1. A01HPOM

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 3 nuts and engine mounting insulator RH.

      Tech Tips

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

  69. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01HR32

      Remove the 3 bolts and drive shaft bearing bracket.

  70. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01HR4C

      Remove the 3 bolts and engine mounting bracket RH.

  71. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY


    1. Using the transmission jack attachment, set the automatic transaxle assembly on a transmission jack.

      Note


      • Secure the automatic transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.

      • To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the automatic transaxle assembly.

      • Hold the engine assembly with a suitable adapter, such as a rope, during the operation.

    2. A01HP5S

      Remove the 9 bolts and automatic transaxle assembly.

      Note

      To prevent damage to the knock pins, do not pry between the automatic transaxle assembly and engine.

  72. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01HOVPE04

      Using SST, hold the crankshaft pulley.

      SST
      09213-54015
      09330-00021
      91551-80650
    2. A01HMYY

      Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly, and rear drive plate spacer.

  73. INSTALL ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.