ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. 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

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  5. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  6. REMOVE NO. 1 ENGINE COVER

    A01VB0D

    1. Detach the 4 clips and remove the No. 1 engine cover.

      Note

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

  7. REMOVE NO. 1 ENGINE UNDER COVER

    A01V8LW

    1. Remove the 4 bolts and 2 screws.

    2. Remove the 10 clips and No. 1 engine under cover.

  8. REMOVE FRONT FLOOR COVER

    Click here

  9. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01V7Z9

      Remove the bolt, clip and No. 2 engine under cover.

  10. REMOVE FRONT FLOOR COVER RH


    1. A01VB58

      Loosen the 3 nuts and remove the 3 clips and front floor cover RH.

  11. REMOVE REAR ENGINE UNDER COVER RH

    Click here

  12. REMOVE REAR ENGINE UNDER COVER LH


    1. A01V8KH

      Remove the 2 clips and rear engine under cover LH.

  13. DRAIN ENGINE COOLANT

    Click here

  14. DRAIN ENGINE OIL

    Click here

  15. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  16. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

    Click here

  17. DRAIN TRANSFER OIL

    Click here

  18. REMOVE FRONT BUMPER COVER (for Automatic Transaxle)

    Click here

  19. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  20. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  21. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  22. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    A01VAFO

    1. Remove the bolt and loosen the nut.

    2. Detach the 2 wire harness clamps.

    3. Detach the hook of the battery clamp sub-assembly from the front battery bracket, and then remove the battery clamp sub-assembly.

  23. REMOVE BATTERY INSULATOR

  24. REMOVE BATTERY

  25. REMOVE BATTERY TRAY

  26. REMOVE FRONT BATTERY BRACKET

    A01V888

    1. Detach the 2 wire harness clamps.

    2. Remove the 4 bolts and front battery bracket.

  27. REMOVE BATTERY BRACKET REINFORCEMENT

    A01V9R6

    1. Remove the 2 bolts and battery bracket reinforcement.

  28. REMOVE RADIATOR ASSEMBLY (for Automatic Transaxle)

    Click here

  29. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  30. REMOVE NO. 3 AIR HOSE

    Click here

  31. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. Disconnect the PCV hose.

    2. Loosen the hose clamp and disconnect the air cleaner hose.

    3. A01V9SS

      Disconnect the mass air flow meter connector and wire harness clamp.

    4. Detach the 3 clips and remove the air cleaner cap sub-assembly.

  32. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  33. REMOVE AIR CLEANER CASE


    1. A01V798

      Remove the 3 bolts and air cleaner case.

  34. REMOVE AIR CLEANER SUPPORT


    1. A01V7GO

      Remove the 2 nuts and air cleaner support.

  35. REMOVE FUEL FILTER ASSEMBLY


    1. A01V990

      Slide the 2 clips and disconnect the 2 fuel hoses.

    2. Remove the bolt and fuel filter assembly.

  36. REMOVE AIR CLEANER BRACKET


    1. A01V932

      Disconnect the glow plug relay and level warning switch connector.

    2. A01V9XW

      Detach the 3 wire harness clamps.

    3. A01V7CK

      Disconnect the 2 fuel hoses from the air cleaner bracket.

    4. Remove the 3 bolts and air cleaner bracket.

  37. REMOVE ECM

    Click here

  38. DISCONNECT HOSES AND CONNECTORS


    1. Remove the engine room relay block and junction block cover.

    2. A01VA5K

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

    3. A01V8MS

      Remove the nut.

    4. Detach the 2 claws and disconnect the engine wire.

    5. A01V9ME

      Remove the bolt and disconnect the engine wire cover clamp and engine wire harness clamp.

    6. Remove the nut and disconnect the starter wire.

    7. A01V6YWC01
      *A for Manual Transaxle
      *B for Automatic Transaxle

      Remove the bolt from the wire harness clamp bracket.

    8. A01V9Z0

      for Manual Transaxle:

      Detach the clamp, remove the bolt and disconnect the ground cable from the manual transaxle assembly.

    9. A01V9GA

      for Manual Transaxle:

      Detach the wire harness clamp and disconnect the 2 connectors.

    10. A01VAIV

      for Manual Transaxle:

      Remove the bolt and disconnect the wire harness from the manual transaxle assembly.

    11. A01VA5W

      for Automatic Transaxle:

      Disconnect the transaxle ECM connector and detach the 2 wire harness clamps.

    12. for Automatic Transaxle:

      Remove the bolt and disconnect the ground cable from the automatic transaxle.

    13. A01V7J2

      for Automatic Transaxle:

      Detach the 2 clamps and disconnect the transaxle shift position switch connector.

    14. A01V6YC

      Detach the 3 wire harness clamps from the 3 wire harness brackets.

    15. A01V807

      for DPF:

      Detach the 2 wire harness clamps and disconnect the 4 injector driver connectors.

    16. A01V8ZG

      for DPF:

      Remove the 2 nuts and injector driver assembly.

    17. A01VAQM

      for CCo:

      Detach the wire harness clamp and disconnect the 4 injector driver connectors.

    18. for CCo:

      Remove the 2 nuts and injector driver assembly.

    19. A01V7J8

      Slide the clip and disconnect the vacuum pump hose from the vacuum pump assembly.

  39. DISCONNECT INLET HEATER WATER HOSE


    1. A01VAU0

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

  40. DISCONNECT OUTLET HEATER WATER HOSE


    1. Slide the clamp and disconnect the outlet heater water hose from the No. 3 water by-pass pipe.

  41. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    A01V9UW

    1. Slide the clamp and disconnect the radiator hose sub-assembly from the cylinder head sub-assembly.

  42. REMOVE INTERCOOLER AIR HOSE

    Click here

  43. DISCONNECT NO. 2 WATER BY-PASS HOSE


    1. A01V9LP

      Slide the clamp and disconnect the No. 2 water by-pass hose from the No. 4 water by-pass pipe.

  44. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01VAIP

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

  45. REMOVE RADIATOR RESERVOIR ASSEMBLY

    A01VB5K

    1. Slide the clamp and disconnect the water by-pass hose from the radiator reservoir assembly.

    2. Remove the 2 bolts and radiator reservoir assembly.

  46. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A01V98H

      Remove the bolt and disconnect the discharge hose sub-assembly.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

    3. Disconnect the cooler compressor connector.

  47. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the bolt and disconnect the suction hose sub-assembly.

    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.

  48. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


    1. A01V7AD

      Remove the 2 pins.

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

  49. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)


    1. A01VA4O

      Remove the nut and clip, and disconnect the transmission control cable assembly from the transmission control cable bracket.

  50. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)


    1. A01V9ET

      Remove the 4 bolts and disconnect the clutch release cylinder assembly and clutch flexible hose bracket.

  51. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  52. SECURE STEERING WHEEL

  53. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  55. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  56. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  57. DISCONNECT FRONT SPEED SENSOR LH

    Click here

  58. DISCONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  59. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  60. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  61. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  62. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  63. REMOVE FRONT AXLE ASSEMBLY LH

    Click here

  64. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  65. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  66. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  67. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01V9DQ

      Remove the 4 bolts and front suspension member reinforcement LH.

  68. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  69. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for Automatic Transaxle)

    Click here

  70. REMOVE FUEL HOSE PROTECTOR


    1. A01V9WF

      Remove the fuel hose protector from the cylinder head sub-assembly.

  71. INSTALL ENGINE HANGER


    1. A01V9SAC01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

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

      Tech Tips

      Part No.
      No. 1 Engine Hanger 12281-26040
      No. 2 Engine Hanger 12282-26010
      Bolt 91552-81025 or 90105-W0042

      • 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.

  72. REMOVE ENGINE WITH TRANSAXLE


    1. A01VA2W

      Remove the 6 bolts and disconnect the front crossmember sub-assembly.

    2. A01V9LA

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

    3. Set an engine lifter underneath the engine.

      Tech Tips

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

    4. A01V96J

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

    5. A01V8IE

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

    6. A01VAHB

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

    7. Remove the 2 bolts and front suspension member sub-assembly.

    8. Carefully remove the engine with transaxle 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.

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

    10. A01V9AR

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

  73. REMOVE NO. 1 AIR TUBE


    1. A01VB3NC01
      *A for Manual Transaxle
      *B for Automatic Transaxle

      Loosen the hose clamp, and remove the 2 bolts and No. 1 air tube.

  74. REMOVE STARTER ASSEMBLY

    Click here

  75. REMOVE ENGINE WIRE

    Click here

  76. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01VADA

      for Manual Transaxle:

      Remove the 3 bolts and front engine mounting bracket.

    2. A01VAEJ

      for Automatic Transaxle:

      Remove the 4 bolts and front engine mounting bracket.

  77. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01VB0F

      Remove the 4 bolts and rear engine mounting bracket.

  78. REMOVE ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. A01V6TDC01
      *A for Manual Transaxle
      *B for Automatic Transaxle

      Remove the 4 bolts and engine mounting bracket LH from the transaxle assembly.

  79. REMOVE OIL PAN INSULATOR


    1. A01V9PE

      Remove the 2 bolts and oil pan insulator.

  80. REMOVE STIFFENER PLATE RH


    1. A01VAZG

      Remove the 4 bolts and stiffener plate RH.

  81. REMOVE STIFFENER PLATE LH


    1. A01V6RJ

      Remove the 4 bolts and stiffener plate LH.

  82. FIX ENGINE ASSEMBLY


    1. Using wooden blocks or plate lift attachments, set the engine on a flat surface.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • Never install attachments to the oil pan of the engine assembly or transaxle as doing so may deform the oil pan.

      • Perform this step while supporting the engine assembly using a sling device and chain block.

  83. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  84. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

    Click here

  85. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  86. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  87. REMOVE FLYWHEEL WITH DAMPER ASSEMBLY (for Manual Transaxle)


    1. A01V9EJN01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A01V7A0

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

  88. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)


    1. A01V9CJ

      Remove the 8 bolts, rear drive plate spacer, drive plate and ring gear sub-assembly, and front drive plate spacer.

  89. INSTALL ENGINE TO ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.


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

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

  90. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01V8FQ

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

  91. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01V8Y0C01
      *A for Manual Transaxle
      *B for Automatic Transaxle

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

  92. 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. A01VA4W

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