ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. PRECAUTION

    CAUTION:

    The engine assembly with transaxle 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 engine 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.

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  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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  3. DISCHARGE FUEL SYSTEM PRESSURE

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  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. SECURE STEERING WHEEL

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  6. REMOVE FRONT WHEELS

  7. 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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  8. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 6 bolts, 8 screws, 3 clips and No. 1 engine under cover.

  9. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 2 bolts, 2 screws, clip and No. 2 engine under cover.

  10. REMOVE FLOOR UNDER COVER LH

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  11. SEPARATE FRONT FENDER LINER LH


    1. Remove the 3 screws, 3 clips and separate the front fender liner LH.

  12. SEPARATE FRONT FENDER LINER RH


    1. Remove the 2 screws, 3 clips and separate the front fender liner RH.

  13. REMOVE FRONT FENDER APRON SEAL LH


    1. A002AEW

      Remove the 2 bolts, clip and front fender apron seal LH.

  14. REMOVE FRONT FENDER APRON SEAL RH


    1. A0027LJ

      Remove the 2 bolts, clip and front fender apron seal RH.

  15. DRAIN ENGINE OIL

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  16. DRAIN ENGINE COOLANT

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  17. DRAIN AUTOMATIC TRANSAXLE FLUID

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  18. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  19. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

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  20. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH

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  21. REMOVE RADIATOR SIDE SEAL RH

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  22. REMOVE COOL AIR INTAKE DUCT SEAL

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  23. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A002AVB

      Lift the rear of the No. 1 engine cover sub-assembly to disengage it from the 2 pins.

      Note

      Attempting to disengage both front and rear pins at the same time may cause the No. 1 engine cover sub-assembly to break.

    2. Lift the front of the No. 1 engine cover sub-assembly to disengage it from the pin and remove it.

  24. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A00283J

      Remove the 2 bolts and inlet air cleaner assembly.

  25. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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  26. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly.

  27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A002C7D

      Remove the 2 bolts and air cleaner case sub-assembly.

  28. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

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  29. REMOVE RESERVOIR BRACKET

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  30. REMOVE BATTERY


    1. A002B5G

      Loosen the nut, and disconnect the cable from the positive (+) battery terminal.

    2. Loosen the nut, and remove the bolt and battery clamp.

    3. Remove the battery and battery tray.

  31. DISCONNECT NO. 1 RADIATOR HOSE


    1. A002AZ0

      Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.

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

  32. DISCONNECT NO. 2 RADIATOR HOSE


    1. A002C2Z

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

  33. DISCONNECT INLET HEATER WATER HOSE


    1. A002A51

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

  34. DISCONNECT OUTLET HEATER WATER HOSE


    1. A002AYFC01
      *1 Inlet Heater Water Hose
      *2 Outlet Heater Water Hose A
      *3 Outlet Heater Water Hose B

      Disengage the 2 claws and disconnect the inlet heater water hose and outlet heater water hose A.

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

  35. DISCONNECT INLET NO.1 OIL COOLER HOSE


    1. A002BM4

      Slide the clip and disconnect the inlet No.1 oil cooler hose from the automatic transaxle assembly.

  36. DISCONNECT OUTLET NO.1 OIL COOLER HOSE


    1. A0028CU

      Slide the clip and disconnect the outlet No.1 oil cooler hose from the automatic transaxle assembly.

  37. REMOVE STARTER ASSEMBLY

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  38. DISCONNECT ENGINE WIRE


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

    2. A0027IC

      Remove the bolt and separate the earth wire.

    3. Remove the nut from the engine room relay block assembly.

    4. Disconnect the 3 wire clamps.

    5. A002A8Z

      Disconnect the 4 connectors from the engine room relay block assembly.

    6. Using a screwdriver, disengage the claw and separate the engine wire from the engine room relay block assembly.

    7. A00279J

      Pull up the lock lever while pushing the lock on the lever to disconnect the ECM connector.

      Note

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

    8. Disengage the 2 wire harness clamps.

  39. REMOVE NO. 1 AIR CLEANER BRACKET


    1. A0028SZ

      Disconnect the 2 wire clamps.

    2. Remove the bolt and No. 1 air cleaner bracket from the battery carrier.

  40. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A002B6Y

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

    2. A0027H5

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

  41. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A002B3E

      Remove the 2 bolts and No. 2 engine mounting stay RH.

  42. REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. A002BO1

      Remove the 4 bolts and engine moving control rod bracket.

  43. REMOVE ENGINE MOVING CONTROL ROD


    1. A00295O

      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.

  44. DISCONNECT UNION TO VACUUM TUBE HOSE


    1. A00293O

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

  45. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

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  46. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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  47. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  48. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  49. REMOVE FRONT AXLE SHAFT NUT

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  50. SEPARATE FRONT STABILIZER LINK ASSEMBLY

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  51. SEPARATE FRONT SPEED SENSOR

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  52. SEPARATE TIE ROD ASSEMBLY LH

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  53. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  54. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

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  55. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  56. SEPARATE FRONT DRIVE SHAFT ASSEMBLY

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  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

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  58. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

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  59. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING (for LH Side)

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  60. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

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  61. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A0027BY

      Remove the flywheel housing under cover.

  62. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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  63. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A002BOMC01
      B003ZYH Attachment Installation Position

      Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • 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 sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

      • 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.

    2. A00284AC02
      *a Bolt
      *b Nut

      Remove the 6 bolts, 2 nuts and frame side rail plate RH and frame side rail plate LH.

    3. Remove the 6 bolts, 2 nuts and front suspension member rear brace RH and front suspension member rear brace LH.

    4. Operate the engine lifter and 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.

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

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

  64. INSTALL ENGINE HANGERS


    1. A0027VZC10
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts as shown in the illustration.

      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt 91552-81040 or 91552-81025
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  65. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly with transaxle.

  66. REMOVE V-RIBBED BELT

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  67. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

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  68. REMOVE GENERATOR ASSEMBLY

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  69. REMOVE FRONT FRAME ASSEMBLY


    1. A002AGY

      Remove the nut and separate the engine mounting insulator LH.

    2. A002A0U

      Remove the bolt and separate the front engine mounting insulator.

    3. A0027GW

      Remove the nut and separate the engine mounting insulator RH.

    4. Remove the front frame assembly.

    5. Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle on a flat level surface.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A0026WI

      Remove the hole plug from the front frame assembly.

    2. A002B2Z

      Remove the 3 nuts and front engine mounting insulator.

  71. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A0028LC

      Remove the 2 hole plugs from the front frame assembly.

    2. A002BXS

      Remove the 3 nuts and engine mounting insulator LH.

  72. REMOVE ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. A0029DX

      Remove the 2 hole plugs from the front frame assembly.

    2. A0029K1

      Remove the 3 nuts and engine mounting insulator RH.

  73. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A0028HM

      Remove the 3 bolts and drive shaft bearing bracket.

  74. REMOVE ENGINE MOUNTING BRACKET RH


    1. A002C62

      Remove the 3 bolts and engine mounting bracket RH.

  75. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

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  76. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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  77. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

      • 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.

  78. REMOVE ENGINE HANGERS


    1. A002BSHC09
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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