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. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. REMOVE NO. 2 CYLINDER HEAD COVER

    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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  7. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  8. REMOVE REAR ENGINE UNDER COVER RH


    1. A01KD3G

      Remove the 3 clips and rear engine under cover RH.

  9. REMOVE REAR ENGINE UNDER COVER LH


    1. A01KDLZ

      Remove the 2 clips and rear engine under cover LH.

  10. REMOVE FRONT FLOOR COVER

    Click here

  11. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01KBM5

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

  12. DRAIN ENGINE COOLANT

    Click here

  13. DRAIN ENGINE OIL

    Click here

  14. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  15. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  16. DRAIN TRANSFER OIL

    Click here

  17. REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A01KBF6

      Slide the 2 hose clamps and disconnect the No. 1 and No. 2 water by-pass hoses from the radiator reservoir assembly.

    2. Remove the 2 bolts and radiator reservoir assembly.

  18. REMOVE V-RIBBED BELT

    Click here

  19. REMOVE GENERATOR ASSEMBLY

    Click here

  20. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  21. DISCONNECT COMPRESSOR ASSEMBLY WITH PULLEY


    1. A01KAYA

      Detach the wire harness clamp and disconnect the cooler compressor connector.

    2. A01KB79

      Remove the 2 bolts and 2 nuts.

    3. A01KDBO

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the compressor assembly with pulley from the engine.

      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.

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  24. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  25. REMOVE BATTERY

  26. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  27. REMOVE BATTERY TRAY

  28. REMOVE FRONT BATTERY BRACKET

    Click here

  29. REMOVE BATTERY BRACKET REINFORCEMENT

    Click here

  30. REMOVE ECM

    Click here

  31. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01KBLN

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

  32. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01KAWB

      Remove the No 1 fuel pipe clamp, and then disconnect the fuel tube sub-assembly from the fuel pipe.

      Click here

  33. DISCONNECT WIRE HARNESS AND HOSE


    1. A01KCO9

      Detach the 2 wire harness clamps and remove the bolt.

    2. A01KCCQ

      Disconnect the 2 engine room junction block connectors and remove the nut.

    3. A01KBAY

      Detach the 2 claws and slide the engine wire, and then disconnect the engine wire from the engine room junction block assembly.

    4. for Manual Transaxle:


      1. A01KCQ3

        Disconnect the terminal cap, and then remove the nut and disconnect the starter wire.

      2. Detach the wire harness clamp.

      3. A01KCXE

        Remove the bolt.

      4. Detach the wire harness clamp to disconnect the engine wire from the manual transaxle assembly.

    5. for CVT:


      1. A01KDG1

        Remove the bolt and disconnect the engine wire from the body.

      2. Disconnect the connector from the battery current sensor.

      3. A01KDD2C01
        *1 Engine Room Main Wire
        *2 Engine Wire

        Remove the nut and disconnect the engine room main wire and engine wire from the battery positive terminal.

    6. A01KB98

      Slide the hose clamp and disconnect the connector tube hose from the air tube.

    7. A01KDB0

      Slide the 2 clamps and disconnect the heater water outlet hose and heater water inlet hose from the heater core.

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


    1. A01KC0G

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

    2. A01KCYP

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

  35. REMOVE NO. 3 WATER BY-PASS HOSE (for CVT)


    1. A01KDON

      Detach the clamp, slide the 2 hose clamps and remove the No. 3 water by-pass hose.

  36. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


    1. Move the shift lever to N.

    2. A01KB5Z

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

    3. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

    4. A01KAZM

      Remove the nut and disconnect the transmission control cable assembly from the transmission control cable support.

    5. A01KAUG

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

  37. 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 from the clutch hose bracket.

  38. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  39. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  41. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  42. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  43. DISCONNECT FRONT SPEED SENSOR LH

    Click here

  44. DISCONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  45. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  46. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  47. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  48. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

  51. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  52. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  53. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  54. DISCONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  55. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  56. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  57. REMOVE FLYWHEEL HOUSING UNDER COVER

    Click here

  58. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)

    Click here

  59. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01KDDV

      Remove the 4 bolts and front suspension member reinforcement LH.

  60. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01KCU9

      Remove the 4 bolts and front suspension member reinforcement RH.

  61. INSTALL ENGINE HANGER


    1. A01KD7C

      Disconnect the air fuel ratio sensor connector and detach the clamp to disconnect the fuel tube from the air fuel ratio sensor bracket.

    2. Remove the bolt and air fuel ratio sensor bracket.

    3. A01KDKCC04
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 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 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050

  62. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01KBLH

      Remove the 6 bolts and front crossmember sub-assembly.

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

      A01KBV0C01
      *A for Manual Transaxle *B for CVT

    3. Set an engine lifter underneath the engine.

      Note

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

    4. A01KCKU

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

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

      A01KC8GC01
      *A for Manual Transaxle *B for CVT
    6. A01KBTA

      Remove the 6 bolts and front suspension member rear brace RH and 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. A01KALS

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

      Note

      Do not damage any engine or transaxle components.

      Tech Tips

      Raise the engine with transaxle assembly while keeping it level.

  63. REMOVE STEERING GEAR HEAT INSULATOR (for RHD)

    Click here

  64. REMOVE NO. 5 WATER BY-PASS HOSE (for CVT)


    1. A01KBRG

      Slide the clip and disconnect the No. 5 water by-pass hose from the No. 3 water by-pass pipe.

    2. A01KDP5

      Slide the clip and disconnect the No. 5 water by-pass hose from the oil cooler.

    3. Detach the 2 clamps to remove the No. 5 water by-pass hose.

  65. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE (for CVT)

    Click here

  66. DISCONNECT NO. 2 TRANSMISSION OIL COOLER HOSE (for CVT)

    Click here

  67. REMOVE OIL COOLER (for CVT)

    Click here

  68. REMOVE TRANSMISSION OIL COOLER BRACKET (for CVT)

    Click here

  69. REMOVE STARTER ASSEMBLY


  70. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  71. REMOVE TRANSFER ASSEMBLY

    Click here

  72. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  73. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  74. 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.

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

    Click here

  76. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  77. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  78. REMOVE CLUTCH TUBE (for Manual Transaxle)

    Click here

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

    Click here

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

    Click here

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

    Click here

  82. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  83. 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.

  84. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01KD5P

      Remove the 3 bolts and drive shaft bearing bracket.

  85. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01KCDFC01
      *A for Manual Transaxle
      *B for CVT

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

  86. 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. A01KB2H

      Remove the bolt and radiator reservoir bracket.

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

  87. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01KARK

      Remove the bolt and wire harness clamp bracket.

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