ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle assembly 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.

PROCEDURE


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


  3. REMOVE NO. 1 ENGINE COVER


    1. A004S23E01

      Lift the No. 1 engine cover to detach the 4 clips in the order shown in the illustration and remove the No. 1 engine cover.

      Note

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

  4. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A004RRM

      Remove the 7 clips and radiator support opening cover.

  5. 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.

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  7. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  8. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  9. REMOVE OUTER COWL TOP PANEL


    1. A004TGZE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Remove the 9 bolts and outer cowl top panel.

  10. REMOVE FRONT BUMPER COVER

    Click here

  11. REMOVE FRONT LOWER BUMPER ABSORBER

    Click here

  12. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  13. REMOVE CENTER NO. 4 ENGINE UNDER COVER


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

  14. REMOVE NO. 2 ENGINE UNDER COVER

    Click here

  15. REMOVE REAR ENGINE UNDER COVER LH


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

  16. REMOVE REAR ENGINE UNDER COVER RH


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

  17. DRAIN ENGINE COOLANT

    Click here

  18. DRAIN ENGINE OIL

    Click here

  19. DRAIN MANUAL TRANSAXLE OIL

    Click here

  20. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  21. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  22. REMOVE BATTERY INSULATOR

  23. REMOVE BATTERY

  24. REMOVE BATTERY TRAY

  25. REMOVE BATTERY CARRIER

    Click here

  26. REMOVE RADIATOR ASSEMBLY

    Click here

  27. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  28. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  29. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  30. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  31. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  32. REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A004T0J

      Slide the clamp and disconnect the water by-pass hose assembly from the radiator reservoir assembly.

    2. Slide the clamp and disconnect the No. 2 water by-pass hose assembly from the radiator reservoir assembly.

    3. Remove the 2 bolts and radiator reservoir assembly.

  33. REMOVE WATER BY-PASS HOSE ASSEMBLY


    1. A004TG6

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 1 air tube assembly.

    2. A004T0N

      Remove the water by-pass hose assembly from the water by-pass pipe.

  34. REMOVE RADIATOR HOSE SUB-ASSEMBLY


    1. A004T4M

      Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 air tube assembly.

    2. A004NRW

      Remove the No. 1 radiator hose sub-assembly from the water outlet.

  35. DISCONNECT VACUUM HOSE


    1. A004T31

      Slide the clamp and disconnect the vacuum hose from the No. 2 vacuum hose assembly.

  36. DISCONNECT FUEL HOSE


    1. A004ONV

      Disconnect the fuel hose from the fuel feed pipe sub-assembly.

  37. DISCONNECT NO. 2 FUEL HOSE


    1. Disconnect the No. 2 fuel hose from the fuel feed pipe sub-assembly.

  38. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. A004Q3N

      Slide the clamp and disconnect the water hose sub-assembly from the No. 1 air tube assembly.

  39. DISCONNECT INLET HEATER WATER HOSE


    1. Slide the clamp and disconnect the inlet heater water hose from the No. 1 air tube assembly.

  40. DISCONNECT HOSES AND CONNECTORS


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

    2. A004QQ1

      Disconnect the 2 connectors.

    3. Remove the 2 nuts.

    4. Detach the 2 claws to disconnect the engine wire from the No. 1 engine room relay block.

    5. A004SR6

      Remove the bolt to disconnect the ground cable.

  41. REMOVE FUEL FILTER ASSEMBLY

    Click here

  42. REMOVE FUEL FILTER SUPPORT


    1. A004O95

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

      Note

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

    2. A004N2V

      Disconnect the connector.

    3. Detach the 2 clamps to disconnect the engine wire.

    4. A004QRN

      Detach the clamp to disconnect the wire harness.

    5. Remove the 3 bolts and fuel filter support.

  43. REMOVE AIR CLEANER BRACKET


    1. A004NM9

      Remove the 3 bolts and air cleaner bracket.

  44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A004RW0

      Remove the 2 pins and disconnect the 2 transmission control cable assemblies from the manual transaxle assembly.

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

  45. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A004SJO

      Remove the 4 bolts and disconnect the clutch release cylinder assembly with clutch flexible hose bracket.

  46. SECURE STEERING WHEEL

    Click here

  47. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  48. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  50. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  51. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  52. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  53. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  54. REMOVE FRONT AXLE ASSEMBLY LH

    Click here

  55. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  56. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  58. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  59. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A004SKH

      Remove the 4 bolts and front suspension member reinforcement LH.

  60. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A004QKR

      Remove the 4 bolts and front suspension member reinforcement RH.

  61. REMOVE ENGINE WITH TRANSAXLE


    1. A004NCT

      Remove the bolt to disconnect the cable bracket.

    2. Set an engine lifter underneath the engine assembly.

      Note


      • Place wooden blocks or plate lift attachments so that the engine assembly is level.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan sub-assembly of the engine assembly or transaxle assembly as doing so may deform the oil pan sub-assembly.

    3. A004MXS

      Detach the clamp and disconnect the air conditioner tube and accessory assembly.

    4. Detach the 2 clamps and disconnect the suction pipe sub-assembly.

    5. A004PIY

      Remove the 4 bolts, 3 nuts and engine mounting insulator RH.

    6. A004R8W

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

      Tech Tips

      While holding the bolt in place, loosen the nut.

    7. A004Q01

      Remove the through bolt and nut to disconnect the front engine mounting insulator.

    8. A004ND7

      Remove the 4 bolts and front crossmember sub-assembly.

    9. A004PFK

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

    10. Remove the 2 bolts and front suspension crossmember sub-assembly.

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

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

  62. DISCONNECT REAR ENGINE MOUNTING INSULATOR


    1. A004SN9

      Remove the bolt to disconnect the rear engine mounting insulator.

  63. REMOVE ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine assembly, and then remove the bracket bolts and engine wire from the engine assembly.

  64. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. A004PP0

      Disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    2. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  65. REMOVE STARTER ASSEMBLY

    Click here

  66. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A004Q3J

      Remove the 4 bolts and front engine mounting bracket.

  67. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A004NHA

      Remove the 5 bolts and rear engine mounting bracket.

  68. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  69. INSTALL ENGINE TO ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.


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

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A004R7X

      Remove the 2 bolts and front engine mounting insulator from the front crossmember sub-assembly.

  71. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A004MOG

      Remove the 2 bolts, 2 nuts and rear engine mounting insulator from the front suspension crossmember sub-assembly.

  72. REMOVE ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. A004RWZ

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

  73. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A004PNO

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