ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition 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 REFRIGERATION SYSTEM

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  5. REMOVE FRONT WHEELS

  6. REMOVE OUTER COWL TOP PANEL

    Click here

  7. REMOVE NO. 1 ENGINE COVER


    1. A01LXK6

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear side.

    2. Raise the cover to detach the 3 clips on the front side and remove the No. 1 engine cover.

      Note

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

  8. REMOVE NO. 2 RADIATOR AIR GUIDE


    1. Remove the 7 clips and No. 2 radiator air guide.

  9. REMOVE FRONT BUMPER ABSORBER LOWER


    1. Remove the 8 bolts, 4 screws and front lower bumper absorber.

  10. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 11 clips, 6 bolts and No. 1 engine under cover.

  11. REMOVE CENTER NO. 4 ENGINE UNDER COVER (w/ Cover)


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

  12. REMOVE FRONT NO. 3 ENGINE UNDER COVER

    Click here

  13. REMOVE REAR ENGINE UNDER COVER LH


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

  14. REMOVE REAR ENGINE UNDER COVER RH


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

  15. DRAIN ENGINE COOLANT

    Click here

  16. DRAIN ENGINE OIL

    Click here

  17. DRAIN MANUAL TRANSAXLE OIL

    Click here

  18. REMOVE BATTERY


    1. A01M2MY

      Loosen the nut, and separate the positive (+) battery terminal.

    2. Remove the bolt and nut.

    3. Remove the battery clamp sub-assembly and battery clamp bolt.

    4. Remove the battery, battery insulator and battery tray from the battery carrier bracket sub-assembly.

  19. REMOVE BATTERY CARRIER BRACKET SUB-ASSEMBLY

    A01M2A1

    1. Disconnect the 2 clamps and engine wire from the battery carrier bracket sub-assembly.

    2. Remove the 4 bolts and battery carrier bracket sub-assembly.

  20. DISCONNECT NO.2 VACUUM TRANSMITTING HOSE ASSEMBLY

    A01LX0N

    1. Slide the clip and disconnect the No. 2 vacuum transmitting hose assembly from the intake manifold.

  21. REMOVE NO. 3 AIR HOSE

    Click here

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01M1ZX

      Disconnect the mass air flow meter connector.

    2. Slide the clip and disconnect the No. 2 ventilation hose.

    3. Slide the hose clamp and disconnect the air cleaner hose.

    4. Disengage the 2 lock clamps and remove the air cleaner cap sub-assembly.

  23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

    2. A01LZE4

      Remove the 3 bolts and air cleaner case sub-assembly.

  24. REMOVE FUEL FILTER ASSEMBLY

    Click here

  25. DISCONNECT HOSES AND CONNECTORS


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

    2. A01M34N

      Disconnect the 3 connectors from the engine room relay block.

    3. Remove the 2 nuts from the engine room relay block.

    4. Disengage the 2 claws and remove the wire harness from the engine room relay block.

    5. A01LZ0U

      Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.

    6. A01M2ZZ

      Disengage the 2 clamps from the air cleaner bracket.

    7. Remove the 5 bolts, air cleaner bracket with the fuel filter support and glow plug relay assembly.

    8. A01M1KN

      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.

  26. DISCONNECT VACUUM PUMP HOSE

    A01LZ9Y

    1. Slide the clip and disconnect the vacuum pump hose from the cylinder head cover sub-assembly.

  27. DISCONNECT INLET HEATER WATER HOSE

    A01M0PS

    1. Slide the clip and disconnect the inlet heater water hose from the cylinder head sub-assembly.

  28. DISCONNECT OUTLET HEATER WATER HOSE

    A01M1TU

    1. Slide the clip and disconnect the outlet heater water hose from the cylinder head sub-assembly.

  29. DISCONNECT NO. 1 RADIATOR HOSE

    A01M19O

    1. Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  30. REMOVE INTERCOOLER AIR HOSE

    Click here

  31. DISCONNECT WATER BY-PASS HOSE

    A01M1WV

    1. Slide the clip and disconnect the water by-pass hose from the No. 4 water by-pass pipe.

  32. DISCONNECT NO. 2 RADIATOR HOSE

    A01M16J

    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet housing.

  33. REMOVE INJECTOR DRIVER

    Click here

  34. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  35. REMOVE V-RIBBED BELT

    Click here

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

    Click here

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

    Click here

  38. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  39. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01M33X

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

    2. A01M21Y

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

    3. A01M22I

      Remove the bolt and disconnect the transmission control cable assembly from the rear engine mounting insulator.

  40. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01LVX8

      Remove the 5 bolts and disconnect the clutch release cylinder assembly and flexible hose bracket.

  41. SECURE STEERING WHEEL

    Click here

  42. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  43. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  45. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  46. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  47. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  48. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)

    Click here

  49. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  50. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  51. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as the LH side.

  52. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set an engine lifter.

      Note


      • Place a height adjustment attachment and plate lift attachments under the engine assembly with transaxle.

      • Do not position the height adjustment attachment or plate lift attachments under the front crossmember sub-assembly.

      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

    2. A01M16A

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

    3. A01M1SF

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A01LV8O

      Remove the 2 bolts and 2 nuts and disconnect the engine mounting insulator sub-assembly RH.

    5. A01M2O3C01
      *A Type A
      *B Type B

      Remove the through bolt and nut, and separate the engine mounting insulator LH.

      Tech Tips

      When removing the through bolt, keep the nut from rotating.

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

      Note

      Make sure that the engine is clear of all wiring and hoses.

  54. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01LXN8C02
      *A Type A
      *B Type B

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

      Tech Tips

      When removing the through bolt, keep the nut from rotating.

  55. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01LYSSC01
      *A Type A
      *B Type B

      Remove the through bolt and separate the rear engine mounting insulator.

  56. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01M1RS

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

  57. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.


    1. A01LV5Z

      Remove the 2 bolts and disconnect the radiator reservoir tank assembly.

    2. A01M2GQ

      Remove the bolt and separate the cooler pipe clamp bracket from the engine mounting insulator sub-assembly RH.

    3. Disconnect the cooler pipe clamp from the engine mounting insulator sub-assembly RH.

    4. Remove the 3 bolts and engine mounting insulator sub-assembly RH from the vehicle body.

  58. INSTALL ENGINE HANGERS


    1. A01M1CTC01
      *1 No. 1 Engine Hanger (12281-26040)
      *2 No. 2 Engine Hanger (12282-26010)
      A01M03W BOLT (91552-81025 or 90105-W0042)

      Install No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

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

      Tech Tips


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

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

    2. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

  59. DISCONNECT ENGINE WIRE

    Click here

  60. REMOVE NO. 1 AIR TUBE

    Click here

  61. REMOVE STARTER ASSEMBLY

    Click here

  62. REMOVE OIL PAN INSULATOR

    Click here

  63. REMOVE STIFFENER PLATE LH

    Click here

  64. REMOVE STIFFENER PLATE RH

    Click here

  65. REMOVE ENGINE WIRE


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

  66. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  67. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  68. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  69. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01M2XJN01

      Hold the crankshaft pulley with SST.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A01LWBT

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

  70. INSTALL ENGINE TO ENGINE STAND


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

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

  71. REMOVE ENGINE HANGER


    1. Remove the 2 bolts and No. 1 engine hanger and No. 2 engine hanger.