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 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 AIR CONDITIONING 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. 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 FRONT WHEEL OPENING EXTENSION PAD RH

  8. REMOVE ENGINE UNDER COVER RH

  9. REMOVE FRONT FENDER APRON SEAL RH

  10. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

  11. REMOVE ENGINE UNDER COVER LH

  12. REMOVE FRONT FENDER APRON SEAL LH

  13. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug and drain the oil into a container.

    3. Clean the oil drain plug.

    4. Install the oil drain plug with a new gasket.

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

  14. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs and 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. Loosen the 2 cylinder block drain cock plugs.

    3. Remove the radiator cap sub-assembly.

      A01I1TFE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Cylinder Block Drain Cock Plug
      *3 Radiator Drain Cock Plug *4 Air Drain Cock Plug

      Tech Tips

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

  15. DRAIN AUTOMATIC TRANSAXLE FLUID


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

    2. A01I196

      Remove the refill plug and gasket from the automatic transaxle.

    3. A01I1E4

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

    4. A01I1REE04
      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.

    5. Drain automatic transaxle fluid from the automatic transaxle.

    6. A01I1REE04
      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.

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    7. A01I1E4

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

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. A01I196

      Temporarily install the gasket and refill plug to the automatic transaxle.

  16. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01HXU2

      Remove the 9 clips and cool air intake duct seal.

  17. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01I03M

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 clips on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  18. REMOVE INLET NO. 2 AIR CLEANER


    1. A01I03Y

      Disconnect the 2 wire harness clamps and vacuum hose clamp.

    2. Remove the 2 bolts and inlet No. 2 air cleaner from the air cleaner case sub-assembly.

  19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01I1GP

      Disconnect the mass air flow meter connector and wire harness clamp.

    2. A01I13K

      Disconnect the 3 hoses.

    3. Separate the ventilation hose.

    4. A01HYZV

      Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly.

    5. Release the 2 clamps and remove the air cleaner cap with hose.

  20. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01I1C7

      Disconnect the wire harness clamp, connector, vacuum hose and No. 1 fuel vapor feed hose.

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

  22. REMOVE BATTERY


    1. A01I1FZ

      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.

  23. REMOVE INLET NO. 1 AIR CLEANER


    1. A01I18E

      Disengage the pin and remove the inlet No. 1 air cleaner.

  24. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. A01HZB2

      Disengage the claw and disconnect the 2 vacuum hoses.

    2. Remove the 2 bolts and intake air resonator sub-assembly.

  25. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01HXUB

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

  26. REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. A01HXL0

      Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.

  27. REMOVE ENGINE MOVING CONTROL ROD


    1. A01HYHN

      Remove the bolt 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.

  28. SEPARATE EARTH WIRE


    1. A01HZAW

      Remove the 2 bolts and separate the earth wire from the engine assembly.

  29. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A01HYK3

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve.

  30. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A01HY49

      Slide the clip and disconnect the union to check valve hose from the brake booster.

  31. DISCONNECT INLET RADIATOR HOSE


    1. A01I275

      Remove the hose clamp to separate the air fuel ratio sensor wire from the inlet radiator hose.

    2. Remove the hose clamp to separate the No. 3 water by-pass hose from the inlet radiator hose.

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

  32. DISCONNECT OUTLET RADIATOR HOSE


    1. A01I12R

      Slide the clip and disconnect the outlet radiator hose.

  33. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01HZJ2

      Slide the clip and disconnect the No. 3 water by-pass hose from the transmission oil cooler.

  34. DISCONNECT INLET HEATER WATER HOSE


    1. A01I0SG

      Slide the clip and disconnect the inlet heater water hose from the water outlet.

  35. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. A01HZNQ

      Slide the clip and disconnect the water hose sub-assembly from the water outlet.

  36. REMOVE STARTER ASSEMBLY


    1. A01I0ST

      Disconnect the starter connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the starter wire.

    4. A01I1P1

      Remove the 2 bolts and starter.

  37. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. A01HZP6

      Remove the 2 nuts and disconnect the wire clamp.

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

    4. A01I1LS

      Disconnect the 4 connectors.

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

    6. A01I0T6

      Pull up the lever to disconnect the ECM connector.

    7. Disconnect the 2 wire clamps.

  38. REMOVE AIR CLEANER BRACKET


    1. A01HYJI

      Disconnect the 2 wire clamps.

    2. Remove the bolt and air cleaner bracket from the battery carrier.

  39. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Move the shift lever to N.

    2. A01I1L6

      Disconnect the wire harness clamp.

    3. A01HZ8B

      Remove the nut from the control shaft lever.

    4. Remove the clip and disconnect the transmission control cable from the control cable bracket.

  40. DISCONNECT FUEL MAIN TUBE


    1. A01I19J

      Remove the No. 1 fuel pipe clamp.

    2. A01HYYP

      Disconnect the fuel tube connector from the fuel main tube by hand. When the connector and the fuel main tube are stuck, push in and pull on the connector to release it. Pull the connector out of the fuel main tube carefully.

      Text in Illustration
      A01I0B8 Push
      A01HZQC Pull

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

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

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

  41. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01HZ01

      Disconnect the 3 connectors.

    2. Disengage the 2 clamps.

    3. A01HY77

      Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor and magnetic clutch.

    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 moisture and foreign matter from entering them.

  42. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A01HY9H

      Remove the bolt and disconnect the suction hose sub-assembly from the compressor and magnetic clutch.

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

      Note

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

  43. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. A01I12Z

      Remove the 2 nuts and No. 1 exhaust pipe support bracket (for Front Side).

  44. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    1. A01I1OP

      Disconnect the 2 wire harnesses from the clamp.

    2. Disconnect the 2 heated oxygen sensor connectors.

    3. A01HXIJ

      Remove the 2 bolts and No. 1 exhaust pipe support bracket (for Rear Side).

    4. A01HXSE

      Remove the 4 bolts, 4 nuts and front exhaust pipe assembly.

    5. Remove the 3 gaskets from the front exhaust pipe assembly.

  45. SECURE STEERING WHEEL


    1. A01I1X9

      Secure the steering wheel with the seat belt in order to prevent rotation.

      Tech Tips

      This operation is useful to prevent damage to the spiral cable.

  46. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01HY0XE02
      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.

  47. REMOVE FRONT AXLE SHAFT NUT LH


    1. A01HXM0E01

      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.

  48. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  49. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


    1. A01HZ6E

      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.

  50. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  51. SEPARATE FRONT SPEED SENSOR LH


    1. A01HZJG

      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. A01HYY9

      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.

  52. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  53. SEPARATE TIE ROD ASSEMBLY LH


    1. A01HYWV

      Remove the cotter pin and nut.

    2. A01I0Z6E01

      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.

      A01I0NOE02
      Text in Illustration
      *1 Center Nut - -
      *a String *b Grease Application Area
      A01HZQC 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.

  54. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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


    1. A01I1B6

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

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

    Tech Tips

    Perform the same procedure as for the LH side.

  57. SEPARATE FRONT DRIVE SHAFT ASSEMBLY


    1. A01I0AWE01
      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.

  58. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01I16SE01

      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.

  59. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. A01HZI2

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

  60. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A01HY68

      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.

  61. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. A01I18G

      Remove the bolt and No. 1 exhaust pipe support bracket.

  62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. A01HZJB

      Remove the 2 bolts and No. 1 exhaust pipe support bracket sub-assembly.

  63. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A01I1K7

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

      Tech Tips

      There will be one black colored bolt.

  64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01I0ES

      Set the engine lifter.

      Text in Illustration
      A01HYFG Attachment Installation Position

      Note


      • Install height adjustment attachments and plate lift attachments 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 under the oil pan of the engine assembly with transaxle.

      • 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.

    2. A01I1QJ

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

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

    4. Operate the engine lifter, and 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.

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

    5. Install the engine hangers Click here.

  65. REMOVE V-RIBBED BELT


    1. A01HY1T

      Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and remove the V-ribbed belt from the V-ribbed belt tensioner.

    2. While turning the V-ribbed belt tensioner counterclockwise, align its holes, and then insert a 5 mm hexagon wrench into the holes to fix the V-ribbed belt tensioner.

  66. REMOVE GENERATOR ASSEMBLY


    1. A01HY69

      Remove the terminal cap.

    2. Remove the nut and disconnect the wire harness from terminal B.

    3. Disconnect the generator connector from the generator assembly.

    4. Remove the bolt and disconnect the wire harness clamp.

    5. A01HXDG

      Remove the 2 bolts.

    6. A01HYM3

      Remove the 2 bolts and generator assembly.

    7. Disconnect the wire harness clamp and remove the generator bracket.

  67. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

    A01HXJC

    1. Remove the 4 bolts and compressor and magnetic clutch and bracket.

  68. REMOVE TRANSMISSION OIL COOLER


    1. A01HZI5

      Disconnect the breather plug and remove the clamp.

    2. Remove the No. 4 water by-pass hose.

    3. A01HZW8E01
      Text in Illustration
      *1 No. 1 Oil Cooler Outlet Hose
      *2 No. 1 Oil Cooler Inlet Hose

      Remove the No. 1 oil cooler outlet hose and No. 1 oil cooler inlet hose.

    4. A01HYPY

      Remove the 2 bolts and transmission oil cooler with the transmission oil cooler stay from the automatic transaxle assembly.

  69. REMOVE FRONT FRAME ASSEMBLY


    1. A01HXFR

      Disconnect the oil pressure switch connector and 2 clamps.

    2. A01I10Y

      Disconnect the 2 clamps and vacuum switching valve connector.

    3. Remove the bolt and disconnect the front engine mounting insulator assembly.

    4. A01I0S2

      Remove the nut and disconnect the engine mounting insulator LH.

    5. A01HZPU

      Remove the nut and disconnect the engine mounting insulator RH.

    6. Remove the front frame assembly.

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY


    1. A01I064

      Remove the 3 nuts and front engine mounting insulator assembly.

      Tech Tips

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

  71. REMOVE ENGINE MOUNTING INSULATOR LH


    1. A01I0NN

      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.

  72. REMOVE ENGINE MOUNTING INSULATOR RH


    1. A01HYC7

      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.

  73. REMOVE ENGINE WIRE


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

  74. 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. A01I1XE

      Remove the 11 bolts and transaxle.

      Note

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

  75. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01HXGC

      Remove the 3 bolts and engine mounting bracket RH.

  76. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01I0BY

      Remove the 3 bolts and drive shaft bearing bracket.

  77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01I0EWE01

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01HZQA

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

  78. INSTALL ENGINE ON ENGINE STAND


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