ДВИГАТЕЛЬ В СБОРЕ СНЯТИЕ

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle assembly 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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

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  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


  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.

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  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  5. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  6. REMOVE NO. 1 ENGINE UNDER COVER

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  7. DRAIN ENGINE COOLANT

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  8. REMOVE HEADLIGHT ASSEMBLY



  9. REMOVE FRONT LOWER BUMPER ABSORBER

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  10. REMOVE NO. 1 ENGINE COVER


    1. A01V8RZN01

      Lift the No. 1 engine cover to detach the 4 clips in the sequence shown in the illustration 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.

  11. REMOVE FRONT FLOOR COVER

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  12. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01V7Z9

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

  13. REMOVE FRONT FLOOR COVER RH


    1. A01VB58

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

  14. REMOVE REAR ENGINE UNDER COVER RH

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  15. REMOVE REAR ENGINE UNDER COVER LH


    1. A01V8KH

      Remove the 2 clips and rear engine under cover LH.

  16. DRAIN ENGINE OIL

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  17. DRAIN MANUAL TRANSAXLE OIL

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  18. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  19. REMOVE BATTERY CLAMP SUB-ASSEMBLY

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  20. REMOVE BATTERY INSULATOR

  21. REMOVE BATTERY

  22. REMOVE BATTERY TRAY

  23. REMOVE BATTERY CARRIER ASSEMBLY

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  24. REMOVE BATTERY BRACKET REINFORCEMENT

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  25. REMOVE RADIATOR ASSEMBLY

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  26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

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  27. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

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  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

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  29. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  30. REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A01V774

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

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

    3. Remove the 2 bolts and radiator reservoir assembly.

  31. REMOVE WATER BY-PASS HOSE ASSEMBLY


    1. A01V8KK

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 1 air tube assembly.

    2. A01V7HE

      Remove the water by-pass hose assembly from the water by-pass pipe.

  32. REMOVE RADIATOR HOSE SUB-ASSEMBLY


    1. A01V8FJ

      Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 air tube assembly.

    2. A01VB5C

      Remove the radiator hose sub-assembly from the water outlet.

  33. DISCONNECT VACUUM HOSE


    1. A01V9UK

      Slide the clamp and disconnect the vacuum hose from the No. 2 vacuum hose assembly.

  34. DISCONNECT NO. 2 FUEL HOSE


    1. A01VAFB

      Disconnect the No. 2 fuel hose from the fuel feed pipe sub-assembly.

  35. DISCONNECT FUEL HOSE


    1. Disconnect the fuel hose from the fuel feed pipe sub-assembly.

  36. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. A01VA9P

      Slide the clamp and disconnect the water hose sub-assembly from the No. 1 air tube assembly.

  37. DISCONNECT OUTLET HEATER WATER HOSE


    1. A01VAEI

      Slide the clamp and disconnect the outlet heater water hose from the No. 1 air tube assembly.

  38. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 engine room relay block cover.

    2. A01VB33

      Disconnect the 3 connectors.

    3. A01V7VR

      Remove the nut.

    4. Detach the 2 claws to disconnect the engine wire from the No. 1 engine room relay block.

    5. A01V7AS

      Remove the bolt to disconnect the ground cable.

  39. REMOVE FUEL FILTER ASSEMBLY

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  40. REMOVE GLOW PLUG RELAY ASSEMBLY


    1. Disengage the glow plug relay assembly from the ECM bracket.

  41. REMOVE FUEL FILTER SUPPORT


    1. A01V8V2

      Raise the lever while pushing the lock on the lever, and disconnect the ECM connector.

      Note

      After disconnecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the ECM connector.

    2. A01V8YI

      Disconnect the connector.

    3. Detach the 4 clamps to disconnect the engine wire.

    4. Detach the clamp to disconnect the wire harness.

    5. A01VAM5

      Remove the 3 bolts and fuel filter support.

    6. Remove the nut and fuel filter support stay.

  42. REMOVE AIR CLEANER BRACKET


    1. A01V9F8

      Remove the 3 bolts and air cleaner bracket.

  43. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01V7MK

      Remove the 2 pins and disconnect the 2 transmission control cable assemblies from the manual transaxle assembly.

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

  44. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

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  45. SECURE STEERING WHEEL

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  46. REMOVE COLUMN HOLE COVER SILENCER SHEET

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  47. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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

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  49. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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  50. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT

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  51. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01V8BA

      Remove the 2 bolts and front suspension member reinforcement LH.

  52. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01V9JR

      Remove the 2 bolts and front suspension member reinforcement RH.

  53. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

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  54. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  55. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01VAHO

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

  56. 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. A01V6Z1

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

    3. A01V8ZK

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A01VAXC

      Detach the 2 clamps and disconnect the air conditioner tube and accessory assembly.

    5. Detach the 2 clamps and disconnect the suction pipe sub-assembly.

    6. A01V7RT

      Remove the 4 bolts, 3 nuts and engine mounting insulator sub-assembly RH.

    7. A01V8ON

      Remove the bolt and nut to remove the engine mounting insulator LH.

      Tech Tips

      While holding the bolt in place, loosen the nut.

    8. A01V9M3

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

      Tech Tips

      When removing the bolt, keep the nut from rotating.

    9. 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.

    10. Using an engine sling device and engine lift, secure the engine assembly with transaxle.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedures 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.

  57. DISCONNECT REAR ENGINE MOUNTING INSULATOR


    1. A01V7VB

      Remove the bolt to disconnect the rear engine mounting insulator.

  58. REMOVE ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine assembly, and then remove the bracket bolts and engine wire from the engine assembly.

  59. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. Disconnect the compressor outlet elbow to the turbocharger sub-assembly.

    2. A01V7ZL

      Disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    3. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  60. REMOVE NO. 1 CLUTCH HOUSING COVER

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  61. REMOVE NO. 2 MANIFOLD STAY

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  62. REMOVE STARTER ASSEMBLY

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  63. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01V6RX

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

  64. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01V9AJ

      Remove the 5 bolts and rear engine mounting bracket from the manual transaxle assembly.

  65. REMOVE ENGINE MOUNTING BRACKET LH


    1. A01V7RJ

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

  66. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. A01V6ST

      Remove the 6 bolts and manual transaxle assembly from the engine assembly.

  67. 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 assembly while it is suspended, as doing so is dangerous.


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

  68. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01VADF

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

  69. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A01VAY1

      Remove the 2 bolts, 2 nuts and rear engine mounting insulator from the front suspension crossmember sub-assembly.

  70. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01V8U4

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