ENGINE ASSEMBLY REMOVAL

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 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.
RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM (for TMC, TMMR Made)
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.
RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM (for TMMK Made)
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.
DISCHARGE FUEL SYSTEM PRESSURE

Click here
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
REMOVE FRONT WHEELS
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
REMOVE ENGINE UNDER COVER LH
REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
REMOVE ENGINE UNDER COVER RH
REMOVE FRONT FENDER APRON SEAL LH
REMOVE FRONT FENDER APRON SEAL RH
DRAIN ENGINE OIL
1. Remove the oil filler cap.
2. Remove the oil pan drain plug and gasket, and drain the engine oil into a container.
3. Clean the oil pan drain plug and install a new gasket and the oil pan drain plug.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }

DRAIN ENGINE COOLANT

Note

Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Text in Illustration

*1 Engine Under Cover LH

*a Hose

Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.
Loosen the radiator drain cock plug.

Text in Illustration
*1	Engine Under Cover LH
*a	Hose

Text in Illustration
*1	Radiator Cap Sub-assembly
*2	Radiator Drain Cock Plug

Remove the radiator cap sub-assembly. Then drain the engine coolant.

Tech Tips

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

Disconnect the hose from the radiator drain cock.

DRAIN AUTOMATIC TRANSAXLE FLUID

Remove the front wheel opening extension pad LH, engine under cover LH and front fender apron seal LH.
Remove the refill plug and gasket from the automatic transaxle assembly.

Text in Illustration
*1	No. 1 Transmission Oil Filler Tube
*2	Overflow Plug
*3	Hexagon Socket Wrench

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

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 assembly.

Drain automatic transaxle fluid from the automatic transaxle assembly.

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 assembly.

Torque:: 0.8 N*m { 8 kgf*cm, 7 in.*lbf }

Text in Illustration
*1	No. 1 Transmission Oil Filler Tube
*2	Overflow Plug
*3	Hexagon Socket Wrench

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

Torque:: 40 N*m { 408 kgf*cm, 29 ft.*lbf }

Install a new gasket and the refill plug to the automatic transaxle assembly.

Torque:

49 N*m { 500 kgf*cm, 36 ft.*lbf }

REMOVE COOL AIR INTAKE DUCT SEAL (for TMC, TMMR Made)
1. Remove the 9 clips and cool air intake duct seal.
REMOVE COOL AIR INTAKE DUCT SEAL (for TMMK Made)
1. Remove the 9 clips and cool air intake duct seal.
REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
1. Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the engine cover.
  
  Note
  
  Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.
REMOVE INLET AIR CLEANER ASSEMBLY
1. Remove the 2 bolts and inlet air cleaner assembly.
REMOVE AIR CLEANER CAP SUB-ASSEMBLY
1. Disconnect the vacuum switching valve assembly from the air cleaner hose.
2. Disconnect the mass air flow meter connector and 2 wire harness clamps from the air cleaner cap sub-assembly.
3. Separate the fuel vapor feed hose from the air cleaner hose.
4. Disconnect the ventilation hose from the cylinder head cover.
5. Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.
6. Release the 2 clamps and remove the air cleaner cap sub-assembly.
REMOVE AIR CLEANER FILTER ELEMENT
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
1. Disconnect the wire harness clamp.
2. Remove the 2 bolts and air cleaner case sub-assembly.
REMOVE BATTERY
1. 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.
DISCONNECT NO. 1 RADIATOR HOSE
1. Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.
2. Disconnect the No. 1 radiator hose.
DISCONNECT NO. 2 RADIATOR HOSE
1. Disconnect the No. 2 radiator hose.
DISCONNECT INLET HEATER WATER HOSE
1. Disconnect the inlet heater water hose.
DISCONNECT OUTLET HEATER WATER HOSE
1. Disconnect the outlet heater water hose.
DISCONNECT OUTLET NO. 1 OIL COOLER HOSE
1. Disconnect the outlet No. 1 oil cooler hose from the automatic transaxle assembly.
DISCONNECT INLET NO. 1 OIL COOLER HOSE
1. Disconnect the inlet No. 1 oil cooler hose from the automatic transaxle assembly.
REMOVE STARTER ASSEMBLY (for 1.6 kW Type)
1. Disconnect the starter connector.
2. Open the terminal cap, remove the nut and disconnect the starter wire.
3. Remove the 2 bolts and starter assembly.
REMOVE STARTER ASSEMBLY (for 1.7 kW Type)
1. Disconnect the starter connector.
2. Open the terminal cap, remove the nut and disconnect the starter wire.
3. Remove the 2 bolts and starter assembly.
DISCONNECT ENGINE WIRE
1. Remove the No. 1 relay block cover.
2. Remove the 2 nuts and disconnect the wire clamp.
3. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
4. Disconnect the 4 connectors.
5. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
6. Pull up the lever to disconnect the ECM connector.
7. Disconnect the 2 wire clamps.
REMOVE NO. 1 AIR CLEANER BRACKET
1. Disconnect the 2 wire clamps.
2. Remove the bolt and No. 1 air cleaner bracket.
DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
1. Remove the nut and disconnect the transmission control cable from the control shaft lever.
2. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.
REMOVE NO. 2 ENGINE MOUNTING STAY RH
1. Remove the 2 bolts and No. 2 engine mounting stay RH.
SEPARATE EARTH WIRE
1. Remove the bolt and separate the earth wire from the engine moving control rod bracket.
REMOVE ENGINE MOVING CONTROL ROD BRACKET
1. Remove the 4 bolts and engine moving control rod bracket.
REMOVE ENGINE MOVING CONTROL ROD
1. 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.
DISCONNECT UNION TO CONNECTOR TUBE HOSE (for LHD)
1. Disconnect the union to connector tube hose.
DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)
1. Disconnect the union to check valve hose.
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the bolt.
2. Disconnect the 2 connectors.
3. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor assembly with pulley.
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 entry of moisture and foreign matter.
DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (for TMC, TMMR Made)
1. Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor assembly with pulley.
2. Remove the O-ring from the No. 1 cooler refrigerant suction hose.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made)
1. Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.
2. Remove the O-ring from the suction hose sub-assembly.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
DISCONNECT FUEL TUBE SUB-ASSEMBLY
1. Release the claw and remove the No. 1 fuel pipe clamp.
2. Pinch the fuel tube connector and then pull out the fuel main tube.
  Note
  - Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector.
  - Disconnect the connector by hand.
  - Do not bend, fold or rotate the nylon tube.
  - If the pipe and connector are stuck together, push and pull the connector until it becomes free.
  - Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
REMOVE FRONT EXHAUST PIPE ASSEMBLY
1. Disconnect the heated oxygen sensor connector.
2. 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.
REMOVE FRONT AXLE SHAFT NUT LH
1. 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.
REMOVE FRONT AXLE SHAFT NUT RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
1. for Steel Type:
  1. 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 hexagon wrench to hold the stud bolt.
2. for Aluminum Type:
  1. 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.
SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT SPEED SENSOR LH
1. 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 assembly completely.
2. 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.
SEPARATE FRONT SPEED SENSOR RH

Tech Tips

Use the same procedure described for the LH side.

SEPARATE TIE ROD ASSEMBLY LH

Remove the cotter pin and nut.
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.
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.

Using SST, separate the tie rod assembly LH from the steering knuckle.

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

SEPARATE TIE ROD ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH
1. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.
SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH
1. 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.
SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. 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.
REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH
1. Using a screwdriver, remove the front drive shaft hole snap ring LH.
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
1. 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.
SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
1. 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.
REMOVE FLYWHEEL HOUSING UNDER COVER
1. Remove the flywheel housing under cover.
REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT
1. Turn the crankshaft to gain access to the removal locations of the 6 drive plate and torque converter assembly setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
1. Set an engine lifter.
  
  Text in Illustration
  
  Attachment Installation Position
  Note
  
  Install a height adjustment attachment and plate lift attachment 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 onto the oil pan of the engine assembly with transaxle.
  
  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.
  
  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 or removed from an engine stand.
2. Remove the 4 bolts, 2 nuts, and frame side rail plate RH and LH.
3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.
4. Operate the engine lifter and remove the engine assembly 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.
5. Install engine hangers Click here.
REMOVE ENGINE WIRE
1. Remove the engine wire from the engine with transaxle.
REMOVE V-RIBBED BELT
1. Attach a wrench to the hexagonal portion of the belt tensioner as shown in the illustration, rotate the belt tensioner clockwise, and remove the V-ribbed belt.
REMOVE COMPRESSOR ASSEMBLY WITH PULLEY
1. Remove the 2 bolts and 2 nuts.
2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor assembly with pulley.
  
  Tech Tips
  
  Remove the compressor assembly with pulley from the vehicle with the stud bolts remaining in the compressor assembly with pulley.
REMOVE GENERATOR ASSEMBLY

for 100 A, 130 A Type: Click here

for 150 A Type: Click here
REMOVE FRONT FRAME ASSEMBLY
1. Remove the nut and separate the engine mounting insulator LH.
2. Remove the bolt and separate the front engine mounting insulator.
3. Remove the nut and separate the engine mounting insulator RH.
4. Remove the front frame assembly.
5. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface.
  Note
  - Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally.
  - To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
  - Using an engine sling device and engine lift, secure the engine assembly before service.
REMOVE FRONT ENGINE MOUNTING INSULATOR
1. Remove the 3 nuts and front engine mounting insulator.
  
  Tech Tips
  
  Perform this procedure only when replacement of the front engine mounting insulator is necessary.
REMOVE ENGINE MOUNTING INSULATOR LH
1. 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.
REMOVE ENGINE MOUNTING INSULATOR RH
1. 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.
REMOVE DRIVE SHAFT BEARING BRACKET
1. Remove the 3 bolts and drive shaft bearing bracket.
REMOVE ENGINE MOUNTING BRACKET RH
1. Remove the 3 bolts and engine mounting bracket RH.
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. Remove the 9 bolts and automatic transaxle assembly.
  
  Note
  
  To prevent damage to the knock pins, do not pry between the automatic transaxle assembly and engine.
REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-54015
  
  09330-00021
  
  Tech Tips
  
  SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)
2. Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly, and rear drive plate spacer.
INSTALL ENGINE STAND
1. Install the engine onto an engine stand with the bolts.