ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

Note

When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  3. REMOVE FRONT BUMPER COVER


    1. Remove the front bumper cover Click here.

  4. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator Click here.

  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. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A002MHP

      Remove the 4 bolts and front lower bumper absorber.

  8. REMOVE REAR ENGINE UNDER COVER RH

    Click here

  9. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and under cover.

  10. REMOVE CENTER NO. 4 ENGINE UNDER COVER


    1. A002Q52

      Remove the 2 clips and under cover.

  11. REMOVE NO. 2 ENGINE UNDER COVER


    1. A002NPY

      Remove the 4 clips and under cover.

  12. DRAIN ENGINE COOLANT

    Click here

  13. DRAIN ENGINE OIL

    Click here

  14. DRAIN MANUAL TRANSAXLE OIL

    Click here

  15. DISCONNECT RADIATOR RESERVOIR ASSEMBLY


    1. A002MGB

      Remove the 2 bolts and disconnect the radiator reservoir.

    2. Remove the grommet from the radiator reservoir.

  16. REMOVE V-RIBBED BELT

    Click here

  17. REMOVE GENERATOR ASSEMBLY

    Click here

  18. DISCONNECT NO. 2 RADIATOR HOSE


    1. A002N4S

      Disconnect the radiator hose from the water inlet.

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

    Click here

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

    Click here

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


    1. A002PET

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. A002NGP

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

      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.

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  24. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A002MVU

      Disconnect the cable from the positive (+) battery terminal.

    2. Remove the bolt and loosen the nut.

    3. Remove the battery clamp.

  25. REMOVE BATTERY

  26. REMOVE BATTERY TRAY

  27. REMOVE BATTERY CARRIER


    1. A002QXQ

      Disconnect the 2 wire harness clamps from the battery carrier.

    2. Remove the 2 bolts and disconnect the radiator pipe from the battery carrier.

    3. A002MTI

      Remove the 4 bolts and battery carrier.

  28. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A002MSS

      Remove the 2 clips and disconnect the 2 cables from the transaxle.

    2. A002M8B

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

    3. A002QJZ

      Remove the nut and disconnect the control cable.

  29. DISCONNECT CLUTCH HOSE


    1. A002QQS

      Using a 10 mm union nut wrench, disconnect the clutch hose from the flexible hose tube.

    2. Remove the clip and disconnect the clutch hose.

  30. DISCONNECT NO. 1 RADIATOR HOSE


    1. A002OX9

      Disconnect the radiator hose from the cylinder head.

  31. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A002NL2

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

    2. A002NMT

      Pinch the retainer as illustrated, and then pull the fuel tube connector off of the pipe.

      Note


      • Remove any dirt and foreign matter from the fuel tube connector before performing this step.

      • Do not allow any scratches or foreign matter on the parts when disconnecting the fuel tube connector, as the connector contains the O-rings that seal the pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.

      • If the fuel tube connector and pipe are stuck, push and pull to release them.

  32. DISCONNECT HEATER WATER HOSE


    1. A002N9F

      Disconnect the 2 heater water hoses.

  33. DISCONNECT WIRE HARNESS AND HOSE


    1. A002MF9E02
      Text in Illustration
      *a Lock
      *b Push

      Disconnect the clamp and ECM connector.


      1. Raise the lever while pushing the locks on the levers, 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.

    2. A002PHF

      Remove the 2 nuts from the engine room No. 1 relay block.

    3. Disconnect the 3 engine room No. 1 relay block connectors.

    4. Detach the 2 clamps and disconnect the wire harness.

    5. A002LTA

      Disconnect the battery current sensor connector.

    6. Remove the 2 bolts and disconnect the clamp and engine wire.

    7. A002LYW

      Remove the bolt and disconnect the engine wire.

    8. A002P27

      Disconnect the connector tube hose.

    9. A002PWJ

      Disconnect the vacuum hose.

  34. SECURE STEERING WHEEL ASSEMBLY

    Click here

  35. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  36. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  37. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  38. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  39. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  40. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  41. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedures described for the LH side.

  42. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedures described for the LH side.

  44. REMOVE FRONT AXLE ASSEMBLY LH


    1. Remove the front axle assembly LH Click here.

  45. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedures described for the LH side.

  46. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  47. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  48. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. A002PSP

      Remove the 2 bolt and front lower engine mounting bracket reinforcement.

  49. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A002PAU

      Remove the 4 bolts and front suspension member reinforcement LH.

  50. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A002OOJ

      Remove the 4 bolts and front suspension member reinforcement RH.

  51. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A002QCN

      Remove the bolt and nut.

      Tech Tips

      While holding the nut in place, loosen the bolt.

    2. Remove the front engine mounting insulator from the front engine mounting bracket.

    3. A002PTS

      Remove the 4 bolts and front crossmember.

  52. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set an engine lifter underneath the engine.

      Note

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

    2. A002OIG

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

    3. A002O8O

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

    4. A002NWH

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

    5. A002NS0

      Remove the 2 bolts and front suspension crossmember.

    6. Operate the engine lifter and slowly remove the engine 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.

  53. INSTALL ENGINE HANGER


    1. A002LXV

      Disconnect the air fuel ratio sensor connector and remove the bolt and air fuel ratio sensor bracket.

    2. A002P4PE02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050 or 90105-W0204

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

  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A002LQN

      Remove the bolt and front suspension crossmember from the engine.

  55. REMOVE STARTER ASSEMBLY

    Click here

  56. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  57. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. Remove the manual transaxle assembly Click here.

  58. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  59. REMOVE CLUTCH DISC ASSEMBLY

  60. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  61. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. Remove the clutch release with bearing cylinder assembly Click here.

  62. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  63. INSTALL ENGINE ON ENGINE STAND


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

    2. Remove the 2 bolts and 2 engine hangers.

  64. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A002QAN

    1. Remove the 2 bolts and front engine mounting insulator.

  65. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A002Q8K

    1. Remove the 2 bolts, 2 nuts and engine mounting insulator.

  66. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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

    A002Q0B

    1. Disconnect the cooler pipe clamp.

    2. Remove the 2 bolts, nut and 2 cooler brackets.

    3. A002OA0

      Remove the 3 bolts and engine mounting insulator.

  67. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

    Tech Tips

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

    A002N58

    1. Remove the 4 bolts and engine mounting insulator.