FRONT SUSPENSION MEMBER (When Using the Engine Support Bridge) REMOVAL


  1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  2. SECURE STEERING WHEEL


    1. A01I44I

      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.

  3. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  4. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY


    1. A01I398

      Remove the 4 bolts and inverter tray bracket sub-assembly from the body.

  5. REMOVE FRONT WHEELS

  6. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

  7. REMOVE ENGINE UNDER COVER RH

  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

  9. REMOVE ENGINE UNDER COVER LH

  10. REMOVE FRONT FENDER APRON SEAL LH

  11. REMOVE FRONT FENDER APRON SEAL RH

  12. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01I4EV

      Lift the rear of the No. 1 engine cover sub-assembly to detach the No. 1 engine cover sub-assembly from the 2 pins, and then lift the front of the No. 1 engine cover sub-assembly to detach the No. 1 engine cover sub-assembly from the pin and remove the No. 1 engine cover sub-assembly.

      Note

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

  13. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01I4ED

      Disconnect the heated oxygen sensor connector.

    2. A01I53E

      Remove the 2 bolts, 2 compression springs and 2 nuts.

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

    4. Remove the 2 gaskets from the exhaust manifold converter sub-assembly and front exhaust pipe assembly.

  14. REMOVE FRONT AXLE SHAFT NUT LH


    1. A01I2XWE01

      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.

  15. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  16. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


    1. A01I5DN

      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.

  17. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  18. SEPARATE TIE ROD ASSEMBLY LH


    1. A01I3L8

      Remove the cotter pin and nut.

    2. A01I4CLE01

      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.

      A01I37QE02
      Text in Illustration
      *1 Center Nut - -
      *a String *b Grease Application Area
      A01I679 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.

  19. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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


    1. A01I64T

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

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

    Tech Tips

    Perform the same procedure as for the LH side.

  22. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01I5HEE01
      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.

  23. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  24. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01I5V7E02
      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.

  25. SEPARATE FRONT ENGINE MOUNTING INSULATOR


    1. A01I4UQ

      Remove the 3 nuts and separate the front engine mounting insulator from the front frame assembly.

  26. SEPARATE ENGINE MOUNTING INSULATOR LH


    1. Remove the 2 hole plugs.

    2. A01I4W2

      Remove the 3 nuts and separate the engine mounting insulator LH from the front frame assembly.

  27. SEPARATE ENGINE MOUNTING INSULATOR RH


    1. Remove the 2 hole plugs.

    2. A01I2DM

      Remove the 3 nuts and separate the engine mounting insulator RH from the front frame assembly.

  28. DISCONNECT WIRE HARNESS


    1. Remove the relay block cover.

    2. A01I3ZR

      Disconnect the 4 connectors and wire harness clamp.

    3. A01I48O

      Remove the bolt and separate the earth wire from the body.

    4. A01I5DC

      Pull up the lever to disconnect the ECM connector.

    5. Disconnect the wire harness clamp.

  29. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01I3VG

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

  30. INSTALL ENGINE HANGERS


    1. A01I5GSE02

      Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt 91552-81040 or 91552-81025
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

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

  31. INSTALL ENGINE SUPPORT BRIDGE


    1. A01I3BV

      Disengage the 2 clamps.

    2. Remove the 2 hood support assemblies Click here.

    3. Install SST to the vehicle body as shown in the illustration.

      A01I5T3E01
      Text in Illustration
      *a Support Shaft *b Side Member
      *c Cloth *d Front Side
      *e Correct *f Incorrect
      *g Front Suspension Nut - -
      SST
      09940-10020

      CAUTION:

      Make sure the fuse bolt is not deformed.

      A01I51KE01
      Text in Illustration
      *a Fuse Bolt
      *b Correct
      *c Incorrect

      Note


      • Prevent SST from contacting the vehicle body or windshield.

      • To prevent damage to the engine hood, place pieces of cloth between the engine hood and SST.

      • Lightly shake SST by hand to make sure it is securely installed while performing work.

      • Set the support shafts on level surfaces.

    4. A01I2L3E01
      Text in Illustration
      *a Support Shaft
      *b Sub Beam
      *c Side Member
      *d Threaded Portion

      Turn the threaded portion of each support shaft to adjust its height and make the SST sub beams parallel to the ground.

    5. Connect the chain to the division bar with the shackle at the position shown in the illustration.

      A01I5UYE01
      Text in Illustration
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *a Division Bar *b Shackle

    6. Connect the division bar and No. 1 engine hanger with the shackle.

    7. Connect the 2nd link of the chain to the No. 2 engine hanger.

    8. Make sure the distance between the chain block assembly and division bar is 50 mm (1.97 in.) or more.

      A01I3CKE01
      Text in Illustration
      *a Chain Block Assembly *b Division Bar
      *c 50 mm (1.97 in.) or more - -

    9. Adjust the position of the chain block assembly so that the chain is perpendicular to the SST main beam and sub beams as shown in the illustration.

      A01I683E01
      Text in Illustration
      *a Chain Block Assembly *b Main Beam
      *c Sub Beam *d Dimension (A)
      *e Dimension (B) *f Correct
      *g Incorrect *h Right to Left Adjustment
      *i Front to Rear Adjustment - -

      CAUTION:

      To prevent the engine assembly with hybrid vehicle transaxle assembly from falling, make sure that the dimension (A) and dimension (B) are equal.

    10. Tighten the 6 wing bolts and 2 bolts.

      A01I5O9
      Torque:
      for Bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    11. A01I505E01
      Text in Illustration
      *a Approximately 50 mm (1.97 in.)

      Move the chain block assembly approximately 50 mm (1.97 in.) as shown in the illustration.

    12. A01I4QFE01
      Text in Illustration
      *a Turn

      Tighten the chain block assembly until it cannot be moved any further by hand.

      Note


      • When suspending the engine assembly with hybrid vehicle transaxle assembly, do not tighten the chain block assembly more than 50 N*m (510 kgf*cm, 37 ft.*lbf).

      • Do not shake the engine assembly with hybrid vehicle transaxle assembly excessively while it is being suspended.

  32. INSTALL BELT


    1. A01I3IJ

      Remove the bolt and nut.

    2. A01I3PM

      Loosen the bolt and disconnect the windshield washer jar assembly from the vehicle body.

      Note

      Do not remove the bolt.

    3. Install SST to the vehicle body as shown in the illustration.

      A01I4C3E01
      SST
      09727-00110

    4. Using the SST ratchet buckle, tighten the SST belt until there is no slack.

      A01I4BLE01
      Text in Illustration
      *a Ratchet Buckle - -

  33. REMOVE FRONT FRAME ASSEMBLY


    1. A01I2SB

      Disconnect the 2 clamps.

    2. A01I28FE01
      Text in Illustration
      *a Chain Block Assembly

      Wind the chain with the chain block assembly to lift the engine with automatic transaxle assembly.

      Note


      • When suspending the engine with automatic transaxle assembly, do not tighten the chain block assembly more than 50 N*m (510 kgf*cm, 37 ft.*lbf).

      • Lift the engine with automatic transaxle assembly until the engine is slightly raised off the front frame assembly.

      • Do not lift the engine with automatic transaxle assembly excessively.

    3. A01I5ZFE01
      Text in Illustration
      *a Engine Lifter
      *b Attachment
      A01I43D Attachment Placement Location

      Support the front frame assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

      CAUTION:


      • The front frame assembly is a heavy component. Make sure that it is supported securely.

      • Make sure to secure the front frame assembly to prevent it from dropping.

      Note

      Use the attachments to keep the front frame assembly level.

    4. A01I5RC

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

    5. Remove the 4 bolts, 2 nuts, and front suspension member rear braces RH and LH.

    6. Slowly lower the front frame assembly.

      Note

      When lowering the front frame assembly, be careful not to damage the vehicle body or other components installed to the vehicle.

  34. REMOVE FRONT NO. 1 STABILIZER BRACKET LH


    1. A01I5ZE

      Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.

  35. REMOVE FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    Perform the same procedure as for the LH side.

  36. REMOVE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY


    1. Remove the front stabilizer bar with 2 front stabilizer link assemblies from the front frame assembly.

  37. REMOVE STEERING LINK ASSEMBLY


    1. A01I2YI

      Remove the 2 bolts, 2 nuts and steering link assembly.

      Note

      Keep the nut from rotating while turning the bolt because the nut has its own stopper.

  38. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH


    1. A01I38D

      Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly from the front frame assembly.

      Note

      When removing the bolt, keep the nut from rotating.

    2. Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm sub-assembly.

  39. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  40. REMOVE FRONT SUSPENSION MEMBER DYNAMIC DAMPER


    1. A01I4A4

      Remove the 2 bolts and front suspension member dynamic damper from the front frame assembly.

  41. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER


    1. Remove the 2 front suspension member body mounting front stoppers from the front frame assembly.

  42. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER


    1. Remove the 2 front suspension member body mounting rear stoppers from the front frame assembly.

  43. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION


    1. A01I4DEE01
      Text in Illustration
      *1 Front Suspension Member Body Mounting Front Cushion

      Install SST as shown in the illustration.

      SST
      09830-10010   ( 09830-01010, 09830-01040, 09830-01050 )
      09950-40011   ( 09951-04020, 09952-04010, 09954-04010, 09955-04011, 09958-04011 )
    2. A01I28DE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front suspension member body mounting front cushion from the front frame assembly.

      Note


      • Make sure that the claws of SST are securely hung onto the mounting cushion.

      • Tighten SST slowly and evenly.

      • Be careful as the mounting cushion may fly out.

      • The mounting cushion cannot be reused.

  44. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH


    1. A01I3EBE01
      Text in Illustration
      *1 Front Suspension Member Body Mounting Rear Cushion LH

      Install SST as shown in the illustration.

      SST
      09830-10010   ( 09830-01010, 09830-01040, 09830-01050 )
      09950-40011   ( 09951-04020, 09952-04010, 09954-04010, 09955-04011, 09958-04011 )
    2. A01I4KQE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front suspension member body mounting rear cushion LH from the front frame assembly.

      Note


      • Make sure that the claws of SST are securely hung onto the mounting cushion.

      • Tighten SST slowly and evenly.

      • Be careful as the mounting cushion may fly out.

      • The mounting cushion cannot be reused.

  45. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH

    Tech Tips

    Perform the same procedure as for the LH side.

  46. REMOVE HOLE PLUG


    1. Remove each hole plug from the front frame assembly.