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.

Note

for Manual Transaxle:

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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE


  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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  6. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01KCXMC01
      *A for Half Cover Type
      *B for Full Cover Type

      for Half Cover Type:

      Remove the 6 screws, 5 clips and No. 1 engine under cover.

    2. for Full Cover Type:

      Remove the 2 screws, 4 bolts, 8 clips and No. 1 engine under cover.

  7. REMOVE REAR ENGINE UNDER COVER RH


    1. A01KD3G

      Remove the 3 clips and rear engine under cover RH.

  8. REMOVE REAR ENGINE UNDER COVER LH


    1. A01KD1XC01
      *A for Half Cover Type
      *B for Full Cover Type

      for Half Cover Type:

      Remove the 3 clips and rear engine under cover LH.

    2. for Full Cover Type:

      Remove the 2 clips and rear engine under cover LH.

  9. REMOVE FRONT FLOOR COVER (w/ Canister Pump Module)

    Click here

  10. REMOVE NO. 2 ENGINE UNDER COVER (w/ Canister Pump Module)


    1. A01KD4D

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

  11. DRAIN ENGINE COOLANT

    Click here

  12. DRAIN ENGINE OIL

    Click here

  13. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)


  14. DRAIN TRANSFER OIL (for 4WD/AWD)

    Click here

  15. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)


  16. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  17. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  18. REMOVE BATTERY INSULATOR

    Click here

  19. REMOVE BATTERY

    Click here

  20. REMOVE BATTERY TRAY

    Click here

  21. REMOVE FRONT BATTERY BRACKET

    Click here

  22. REMOVE BATTERY BRACKET REINFORCEMENT

    Click here

  23. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  24. REMOVE AIR CLEANER CASE

    Click here

  25. REMOVE ECM

    Click here

  26. DISCONNECT RADIATOR RESERVOIR ASSEMBLY

    Click here

  27. REMOVE FAN AND GENERATOR V BELT

    Click here

  28. REMOVE GENERATOR ASSEMBLY

    Click here

  29. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  30. REMOVE RADIATOR HOSE HOSE CLAMP

    Click here

  31. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  32. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  33. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  34. REMOVE TRANSMISSION OIL COOLER (for Automatic Transaxle)


  35. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01KCS1

      Remove the No. 1 fuel pipe clamp.

    2. Disconnect the fuel tube connector.

      Click here

  36. DISCONNECT WIRE HARNESS AND HOSE


    1. A01KD3Z

      Remove the terminal cap.

    2. A01KASP

      Remove the nut, and disconnect the clamp and starter wire harness.

    3. A01KDIV

      Remove the bolt. Then disconnect the 2 clamps and wire harness.

    4. A01KD3R

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

    5. Disconnect the 2 connectors, detach the 2 claws from the engine room No. 1 relay block and disconnect the wire harness.

    6. A01KBCQ

      Remove the bolt and disconnect the wire harness.

    7. A01KDMM

      Slide the clip and disconnect the vacuum hose from the No. 1 hose to hose tube.

    8. A01KBHS

      for Manual Transaxle:


      1. Detach the heater hose from the clamp.

      2. Slide the clip and disconnect the heater hose from the cylinder head sub-assembly.

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

    9. A01KBLC

      for Automatic Transaxle:


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

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

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


    1. A01KCZL

      Remove the 4 clips and disconnect the 2 transmission control cables.

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


    1. A01KCMH

      Remove the nut and disconnect the transmission control cable from the control shaft lever.

    2. Remove the clip and disconnect the transmission control cable from the control cable bracket.

  39. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  40. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  42. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  43. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  44. DISCONNECT FRONT SPEED SENSOR LH

    Click here

  45. DISCONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  46. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  47. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  48. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  49. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  50. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  51. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


  53. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH


  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


  55. REMOVE DRIVE SHAFT BEARING BRACKET


    1. Remove the 3 bolts and bracket.

  56. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A01KCC0

      Remove the flywheel housing under cover.

  57. DISCONNECT CLUTCH HOSE (for Manual Transaxle)


    1. A01KBAN

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

    2. Remove the clip and disconnect the clutch hose.

  58. REMOVE FRONT NO. 2 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  59. REMOVE FRONT EXHAUST PIPE SUB-ASSEMBLY

    Click here

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


  61. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD/AWD)

    Click here

  62. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01KDDV

      Remove the 4 bolts and front suspension member reinforcement LH.

  63. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01KCU9

      Remove the 4 bolts and front suspension member reinforcement RH.

  64. INSTALL ENGINE HANGER


    1. A01KBNZC06
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 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 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt

      91552-81025

      91552-81040

  65. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01KBLH

      Remove the 6 bolts and front crossmember sub-assembly.

    2. A01KC92

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

      Note

      While holding the nut in place, loosen the through bolt.

    3. Set an engine lifter underneath the engine.

      Note

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

    4. A01KC7G

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

    5. A01KANR

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

    6. A01KBTA

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

    7. A01KB1J

      Remove the 2 bolts and front suspension crossmember sub-assembly.

    8. 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.

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

    10. A01KDC0

      Remove the through bolt and front suspension crossmember sub-assembly from the engine with transaxle.

      Note

      Do not damage any engine or transaxle components.

      Tech Tips

      Raise the engine with transaxle assembly while keeping it level.

  66. REMOVE STARTER ASSEMBLY

    Click here

  67. REMOVE TRANSFER ASSEMBLY (for 4WD/AWD)

    Click here

  68. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)


  69. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)


  70. 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 transmission as doing so may deform the oil pan.

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

  71. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  72. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

  74. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

  76. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  77. 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 with the bolts.

    2. Remove the 2 bolts and 2 engine hangers.

  78. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A01KAOE

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

  79. 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.

    A01KD9E

    1. Remove the bolt and radiator reservoir bracket.

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

  80. REMOVE ENGINE MOUNTING SPACER

    Tech Tips

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

    A01KD32

    1. Remove the 2 bolts and engine mounting spacer.

  81. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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

    A01KBRO

    1. Remove the bolt and wire harness clamp bracket.

    2. Remove the 4 bolts and engine mounting insulator LH.