ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. INSPECT DRIVE AWAY RELEASE FUNCTION

    Click here

  2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  3. 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.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  5. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  6. REMOVE FRONT WHEEL

  7. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  8. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)

    Click here

  9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A004UBB

      Disconnect the connector and detach the harness clamp.

    2. A004QKP

      Remove the 9 bolts and outer cowl top panel.

  10. REMOVE NO. 1 ENGINE COVER

    Click here

  11. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  12. REMOVE FRONT LOWER BUMPER ABSORBER

    Click here

  13. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  14. REMOVE CENTER NO. 4 ENGINE UNDER COVER


    1. A004RFZ

      Remove the 2 clips and center No. 4 engine under cover.

  15. REMOVE NO. 2 ENGINE UNDER COVER

    Click here

  16. REMOVE REAR ENGINE UNDER COVER RH


    1. Remove the 5 clips and rear engine under cover RH.

  17. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and rear engine under cover LH.

  18. DRAIN ENGINE COOLANT

    Click here

  19. DRAIN ENGINE OIL

    Click here

  20. DRAIN MANUAL TRANSAXLE OIL

    Click here

  21. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  22. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  23. REMOVE BATTERY INSULATOR

  24. REMOVE BATTERY

  25. REMOVE BATTERY TRAY

  26. REMOVE BATTERY CARRIER

    Click here

  27. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    A004SW6

    1. Disconnect the No. 2 vacuum transmitting hose from the intake manifold.

  28. REMOVE NO. 3 AIR HOSE

    Click here

  29. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A004NE9

      Disconnect the mass air flow meter connector.

    2. Disconnect the No. 2 ventilation hose.

    3. Disconnect the air cleaner hose.

    4. Detach the 4 clamps and remove the air cleaner cap.

  30. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  31. REMOVE AIR CLEANER CASE


    1. A004OI4

      Remove the 3 bolts and air cleaner case.

  32. REMOVE FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)

    Click here

  33. REMOVE FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)

    Click here

  34. DISCONNECT HOSES AND CONNECTORS


    1. Remove the engine room No. 1 relay block cover.

    2. Disconnect the current sensor connector.

    3. A004OOT

      Disconnect the 4 connectors.

    4. Remove the 2 nuts.

    5. Detach the 2 claws and remove the engine room No. 1 relay block.

    6. A004SVQ

      Remove the bolt and disconnect the ground cable.

    7. A004NIAE03
      Text in Illustration
      *A for LHD
      *B for RHD

      for LHD:

      Detach the 5 clamps and disconnect the 2 connectors.

    8. for RHD:

      Detach the 3 clamps and disconnect the 2 connectors.

    9. Remove the 5 bolts and air cleaner bracket.

    10. A004N9W

      Detach the 4 clamps and disconnect the wire harness.

    11. A004SFD

      Raise the lever while pushing the lock on the lever, and disconnect the ECM connector.

      Note

      After disconnecting the connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connector.

    12. Disconnect the 2 fuel hoses.

    13. A004PAZ

      Disconnect the vacuum pump hose.

  35. DISCONNECT INLET HEATER WATER HOSE

    A004QAY

  36. DISCONNECT OUTLET HEATER WATER HOSE

  37. DISCONNECT NO. 1 RADIATOR HOSE

    A004NRA

    1. Disconnect the No. 1 radiator hose.

  38. REMOVE INTERCOOLER AIR HOSE

    Click here

  39. DISCONNECT WATER BY-PASS HOSE

    A004TG0

  40. DISCONNECT NO. 2 RADIATOR HOSE

    A004U49

  41. REMOVE INJECTOR DRIVER


    1. A004PQE

      Detach the clamp and disconnect the 4 connectors.

    2. A004OR3

      Remove the 3 screws and injector driver.

  42. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  43. REMOVE FAN AND GENERATOR V BELT

    Click here

  44. DISCONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A004Q9D

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. A004QHK

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the compressor.

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  45. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A004QYB

      Remove the 2 pins.

    2. Remove the 2 clips and disconnect the 2 transmission control cables from the control cable bracket.

  46. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A004MQQ

      Remove the 6 bolts and disconnect the clutch release cylinder and flexible hose bracket.

  47. SECURE STEERING WHEEL

    Click here

  48. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  49. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  50. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  51. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  52. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  53. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  54. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  55. REMOVE FRONT AXLE ASSEMBLY LH

    Click here

  56. REMOVE FRONT AXLE ASSEMBLY RH

    Click here

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  58. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  59. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A004OJN

      Remove the 4 bolts and front suspension member reinforcement LH.

  60. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A004MX1

      Remove the 6 bolts and front crossmember.

  61. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A004NDIE01
      Text in Illustration
      *1 Through Bolt
      *2 Nut

      Remove the through bolt, nut and front engine mounting insulator.

  62. REMOVE ENGINE WITH TRANSAXLE


    1. A004NRT

      Remove the bolt and disconnect the cable bracket.

    2. A004PTL

      Detach the 3 clamps and disconnect the wire harness.

    3. Set an engine lifter underneath the engine.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    4. A004TMO

      Remove the 2 bolts and 2 nuts, and disconnect the engine mounting insulator RH.

    5. A004RKT

      Remove the bolt and nut and disconnect the engine mounting insulator LH.

    6. A004T98

      Remove the 6 bolts and front suspension member rear brace RH and LH.

    7. Remove the 2 bolts and suspension crossmember.

    8. Carefully remove the engine with transaxle from the vehicle.

    9. A004NF0E02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 2 bolts as shown in the illustration.

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

      Tech Tips

      Part No.
      No. 1 engine hanger 12281-26040
      No. 2 engine hanger 12282-26010
      Bolt 91552-81025 or 90105-W0042

      • Insert the claw of the No. 1 engine hanger into the hole of the cylinder head.

      • Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

    10. Attach an engine sling device and hang the engine with a chain block.

  63. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A004UBT

      Remove the 3 bolts, 2 nuts and rear engine mounting insulator.

  64. REMOVE NO. 1 AIR TUBE


    1. A004TSC

      Loosen the hose clamp, and remove the 2 bolts and No. 1 air tube.

  65. REMOVE STARTER ASSEMBLY (for VALEO Made)

    Click here

  66. REMOVE STARTER ASSEMBLY (for DENSO Made)

    Click here

  67. REMOVE ENGINE WIRE

  68. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. Remove the 3 bolts and front engine mounting bracket.

  69. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A004POZ

      Remove the 5 bolts and rear engine mounting bracket.

  70. REMOVE ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. A004U4M

      Remove the 4 bolts and engine mounting bracket LH from the transaxle.

  71. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A004QGM

      Remove the 4 bolts and engine mounting insulator LH from the body.

  72. REMOVE ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. A004Q1F

      Remove the 3 bolts and engine mounting insulator RH from the body.

  73. REMOVE OIL PAN INSULATOR


    1. A004RSW

      Remove the 2 bolts and oil pan insulator.

  74. REMOVE STIFFENER PLATE RH


    1. A004RI9

      Remove the 4 bolts and stiffener plate RH.

  75. REMOVE STIFFENER PLATE LH


    1. A004NZX

      Remove the 4 bolts and stiffener plate LH.

  76. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  77. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  78. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  79. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A004SJ5E02

      Hold the crankshaft pulley with SST.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A004TIY

      Using a T55 "TORX" socket wrench, remove the 8 bolts and flywheel.

  80. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine to an engine stand, and remove the sling device and chain block from the engine.

    2. Remove the 2 bolts, No. 1 and No. 2 engine hangers.