ENGINE ASSEMBLY(w/o Glow Plug Controller) REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

Some of these service operations affect the multi-mode manual transaxle system. Read the precautionary notices concerning the multi-mode manual transaxle system before servicing.

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Note


  • When the manual transaxle assembly or multi-mode manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the manual transaxle assembly or multi-mode manual transaxle assembly 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.

  • After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" using the GTS.

    Click here

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. REGARDING PARTS REMOVAL (for Multi-Mode Manual Transaxle)


    1. Before removing the clutch actuator or multi-mode manual transaxle assembly from the vehicle, perform the Active Test to set the clutch actuator to the "Clamp" position.

      Click here

      Note

      If the actuator is not set to the "Clamp" position, the clutch fluid may spray.

      Tech Tips

      If the clutch actuator cannot be set to the "Clamp" position due to a malfunction (sticking, etc.), then release the clutch fluid pressure through the bleeder plug to prevent the clutch fluid from spraying.

  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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. REMOVE FRONT WHEELS

  6. REMOVE FRONT LOWER BUMPER ABSORBER


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

  7. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 2 bolts, 11 clips and No. 1 engine under cover.

  8. REMOVE CENTER NO. 4 ENGINE UNDER COVER


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

  9. REMOVE FRONT NO. 3 ENGINE UNDER COVER


    1. Remove the 4 clips and front No. 3 engine under cover.

  10. REMOVE REAR ENGINE UNDER COVER LH


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

  11. REMOVE REAR ENGINE UNDER COVER RH


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

  12. DRAIN ENGINE OIL

    Click here

  13. DRAIN ENGINE COOLANT

    Click here

  14. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  15. DRAIN MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)

    Click here

  16. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)


    1. A00YAQ3C01
      A00Y51D Disengage the 2 grommets first.
      A00YA05 Disengage the 2 hooks next.

      Lift the front of the No. 1 engine cover to disengage the 2 grommets from the 2 pins. Then disengage the 2 hooks from the No. 2 engine cover bracket, and remove the No. 1 engine cover.

  17. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  18. REMOVE WATER GUARD PLATE LH (for LHD)

    Click here

  19. REMOVE WATER GUARD PLATE LH (for RHD)

    Click here

  20. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  21. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  22. REMOVE OUTER COWL TOP PANEL (for LHD)

    Click here

  23. REMOVE OUTER COWL TOP PANEL (for RHD)

    Click here

  24. REMOVE BATTERY


    1. A00Y4ZI

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

    2. Remove the nut, bolt, battery clamp sub-assembly and battery clamp bolt.

    3. Remove the battery.

    4. Remove the battery tray.

  25. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A00Y8AZ

      Disconnect the wire harness clamp, connector and ventilation hose.

    2. Loosen the hose clamp.

    3. Unlock the 2 lock clamps and remove the air cleaner cap sub-assembly.

  26. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A00Y8AG

      Remove the air cleaner filter element sub-assembly.

    2. A00Y8J9

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

  27. REMOVE FUEL FILTER ASSEMBLY

    Click here

  28. DISCONNECT WIRE HARNESS


    1. A00Y7C0

      Pull up the lever to disconnect the ECM connector.

    2. Disconnect the 3 wire harness clamps from the fuel filter support.

    3. Remove the No. 1 relay block cover from the engine room relay block and junction block assembly.

    4. A00Y6TS

      Remove the 2 nuts from the engine room relay block and junction block assembly.

    5. Disconnect the 4 wire harness connectors, 2 claws and wire harness from the engine room relay block and junction block assembly.

    6. A00Y7JQ

      Disconnect the 2 wire harness clamps.

    7. A00Y631

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

  29. DISCONNECT WIRE HARNESS (for Multi-Mode Manual Transaxle)


    1. A00YAEZ

      Disconnect the 6 wire harness clamps.

    2. A00YAG9

      Disconnect the 7 connectors.

  30. REMOVE GLOW PLUG RELAY ASSEMBLY


    1. A00Y6KO

      Remove the bolt and disconnect the glow plug relay assembly from the fuel filter support.

    2. Disconnect the wire harness clamp from the fuel filter support.

  31. REMOVE FUEL FILTER SUPPORT


    1. A00Y5WR

      Disconnect the wire harness clamp from the fuel filter support.

    2. Remove the 3 bolts and fuel filter support.

  32. REMOVE AIR CLEANER BRACKET


    1. A00Y608

      Remove the 3 bolts and air cleaner bracket.

  33. REMOVE NO. 2 BATTERY CARRIER


    1. A00Y6DA

      Remove the 4 bolts and No. 2 battery carrier.

  34. REMOVE NO. 3 AIR HOSE


    1. A00Y79M

      Loosen the 2 hose clamps and remove the No. 3 air hose.

  35. REMOVE INTERCOOLER AIR HOSE


    1. A00YBCN

      Loosen the 2 hose clamps and remove the intercooler air hose.

  36. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


    1. A00Y8V7N02

      Remove the 2 clips (A) and disconnect the 2 transmission control cable assemblies from the manual transaxle assembly.

    2. Remove the 2 clips (B) and disconnect the 2 transmission control cable assemblies from the control cable bracket assembly.

    3. A00Y8P6

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

  37. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A00YANA

      Slide the clip and disconnect the union to connector tube hose from the cylinder head cover sub-assembly.

  38. REMOVE WATER BY-PASS HOSE


    1. A00Y9LM

      Slide the clip and disconnect the water by-pass hose from the water inlet.

  39. DISCONNECT NO. 2 RADIATOR HOSE


    1. A00Y7Z8

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

  40. DISCONNECT NO. 1 RADIATOR HOSE


    1. A00Y7LJ

      Slide the clip and disconnect the No. 1 radiator hose from the outlet water sub-assembly.

  41. DISCONNECT INLET HEATER WATER HOSE A (w/o Combustion Type Power Heater)


    1. A00Y654

      Slide the clip and disconnect the inlet heater water hose A from the inlet heater water pipe A.

  42. DISCONNECT INLET HEATER WATER HOSE D (w/ Combustion Type Power Heater)


    1. A00Y654

      Slide the clip and disconnect the inlet heater water hose D from the inlet heater water pipe A.

  43. DISCONNECT OUTLET HEATER WATER HOSE


    1. A00YAP3

      Slide the clip and disconnect the outlet heater water hose from the water by-pass pipe sub-assembly.

  44. REMOVE V-RIBBED BELT

    Click here

  45. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)


    1. A00Y5DQ

      Disconnect the connector.

    2. A00Y53D

      Remove the 2 bolts and 2 nuts.

    3. A00Y8DF

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

    4. Separate the compressor assembly with pulley.

      Tech Tips

      It is not necessary to completely remove the compressor assembly with pulley. With the hoses connected to the compressor assembly with pulley, hang the compressor assembly with pulley on the vehicle body with a rope.

  46. SECURE STEERING WHEEL

    Click here

  47. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  48. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  50. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  51. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  53. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  54. DISCONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)


    1. A00Y6KN

      Using a 10 mm union nut wrench, disconnect the No. 1 clutch hose from the accumulator to flexible hose tube.

    2. Remove the clip and separate the No. 1 clutch hose from the flexible hose bracket.

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

    Click here

  56. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  57. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  58. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  59. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  60. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  61. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set an engine lifter.

      Note


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

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

      • 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. A00Y7W0

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

    3. A00Y8EL

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A00Y7LF

      Remove the 3 nuts and separate the engine mounting insulator sub-assembly RH.

    5. A00Y6QV

      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 assembly with transaxle is clear of all wiring and hoses.

  62. INSTALL ENGINE HANGER


    1. A00Y8MWC03
      *1 No. 1 Engine Hanger (Part No. 12281-33050)
      *2 Bolt (Part No. 91552-81050)
      *a Tab
      A00YA05 Engine Rear

      Install the No. 1 engine hanger with a new bolt as shown in the illustration.

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

      Note


      • Be sure to install the No. 1 engine hanger with the tab contacting the rear side of the hole.

      • Be sure to use a new bolt to install the No. 1 engine hanger.

    2. A00Y6OHC01
      *1 No. 2 Engine Hanger (Part No. 12282-33022)
      *2 Bolt (Part No. 91672-81025)

      Install the No. 2 engine hanger with a new bolt as shown in the illustration.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      Note

      Be sure to use a new bolt to install the No. 2 engine hanger.

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

  63. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A00Y7JM

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

      Tech Tips

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

  64. REMOVE REAR ENGINE MOUNTING INSULATOR


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

      A00Y5VPC01
      *A Type A *B Type B
      *C Type C - -

  65. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A00Y765

      Remove the 4 bolts and engine mounting insulator LH.

  66. 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. A00Y5IN

      Remove the 2 bolts and separate the radiator reserve tank assembly.

    2. A00YAOL

      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.

  67. REMOVE NO. 1 AIR TUBE


  68. REMOVE STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  69. REMOVE STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  70. DISCONNECT WIRE HARNESS (for Manual Transaxle)


  71. DISCONNECT WIRE HARNESS (for Multi-Mode Manual Transaxle)

    Click here

  72. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  73. REMOVE MULTI-MODE MANUAL TRANSAXLE ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  74. REMOVE ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

    Click here

  75. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click here

  76. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  77. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  78. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  79. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  80. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE (for Manual Transaxle)

    Click here

  81. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE (for Multi-Mode Manual Transaxle)

    Click here

  82. REMOVE ENGINE WIRE


    1. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.

  83. REMOVE NO. 2 AIR TUBE


    1. A00YA8T

      Loosen the hose clamp.

    2. Remove the 2 bolts and No. 2 air tube.

  84. REMOVE OUTLET HEATER WATER HOSE A


    1. A00Y84T

      Slide the clip and remove the outlet heater water hose A from the outlet outer water sub-assembly.

  85. REMOVE HARNESS BRACKET


    1. A00Y80Y

      w/o No. 1 Engine Cover:


      1. Remove the 2 nuts and 2 harness brackets.

    2. A00Y5A7

      w/ No. 1 Engine Cover:


      1. Remove the 2 nuts, No. 2 engine cover bracket and 2 harness brackets.

  86. REMOVE SENSOR BRACKET


    1. A00YB0U

      Slide the 2 clips and disconnect the 2 vacuum transmitting hoses.

    2. Remove the nut and sensor bracket.

  87. REMOVE NO. 1 TURBO INSULATOR


    1. A00YBH8

      Remove the 3 bolts and No. 1 turbo insulator.

  88. REMOVE NO. 2 VACUUM PIPE

    Click here

  89. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  90. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET

    Click here

  91. REMOVE NO. 3 MANIFOLD SUPPORT BRACKET

    Click here

  92. REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  93. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A00YAC5

      Disconnect the 2 exhaust gas temperature sensor connectors.

    2. Disengage the 2 harness clamps from the No. 2 timing chain cover.

    3. A00Y7IJ

      Disengage the 2 harness clamps from the harness bracket.

    4. A00Y5AG

      Remove the bolt, 3 nuts and exhaust manifold converter sub-assembly.

  94. REMOVE MANIFOLD SUPPORT BRACKET


    1. A00Y8VV

      Remove the 3 bolts and manifold support bracket.

  95. REMOVE NO. 2 MANIFOLD SUPPORT BRACKET


    1. A00Y8ZP

      Remove the 2 bolts and No. 2 manifold support bracket.

  96. REMOVE TURBOCHARGER STAY

    Click here

  97. REMOVE MANIFOLD STAY

    Click here

  98. SEPARATE INLET TURBO OIL PIPE SUB-ASSEMBLY

    Click here

  99. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  100. REMOVE EXHAUST MANIFOLD

    Click here

  101. REMOVE CYLINDER BLOCK SIDE COVER


    1. A00YAZI

      Remove the bolt, washer plate and cylinder block side cover.

  102. REMOVE CRANK POSITION SENSOR

    Click here

  103. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  104. REMOVE CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  105. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  106. REMOVE CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  107. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  108. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  109. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine assembly to an engine stand.