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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. PRECAUTION

    Note

    After turning the engine 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 ASSEMBLY


    1. B0059VN

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

  7. REMOVE REAR ENGINE UNDER COVER RH


    1. B005A4O

      Remove the 3 clips and rear engine under cover RH.

  8. REMOVE REAR ENGINE UNDER COVER LH


    1. B0057QB

      Remove the 2 clips and rear engine under cover LH.

  9. REMOVE FRONT FLOOR COVER CENTER LH

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  10. DRAIN ENGINE COOLANT

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  11. DRAIN COOLANT (for Intercooler)

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  12. DRAIN ENGINE OIL

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  13. DRAIN AUTOMATIC TRANSAXLE FLUID


  14. DRAIN TRANSFER OIL (for AWD)

    Click here

  15. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  16. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B0057W4

      Remove the 3 clips and No. 1 engine cover sub-assembly.

      Note

      When removing the No. 1 engine cover sub-assembly, make sure to lift it upward. Pulling the No. 1 engine cover sub-assembly towards you may damage the No. 1 engine cover sub-assembly.

  17. REMOVE BATTERY CLAMP SUB-ASSEMBLY

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  18. REMOVE BATTERY INSULATOR

  19. REMOVE BATTERY

  20. REMOVE BATTERY TRAY

  21. REMOVE BATTERY CARRIER ASSEMBLY

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  22. REMOVE BATTERY BRACKET REINFORCEMENT

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  23. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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  24. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  25. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  26. REMOVE ECM

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  27. DISCONNECT RADIATOR RESERVOIR ASSEMBLY


    1. B005ASS

      Remove the 2 bolts and disconnect the radiator reservoir assembly from the radiator reservoir bracket and body.

  28. REMOVE INTAKE AIR CONNECTOR

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  29. REMOVE NO. 2 AIR CLEANER HOSE

    Click here

  30. REMOVE NO. 5 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  31. REMOVE COMPRESSOR OUTLET ELBOW

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  32. REMOVE INTAKE AIR RESONATOR

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  33. REMOVE NO. 1 AIR TUBE

    Click here

  34. REMOVE NO. 2 INTERCOOLER COOLING WATER PIPE


    1. B005ATIC02
      *1 No. 1 Turbo Water Hose
      *2 No. 1 Sub-radiator Hose
      *3 No. 6 Radiator Hose Sub-assembly

      Slide the hose clip and disconnect the No. 6 radiator hose sub-assembly from the No. 2 water by-pass pipe.

    2. Slide the hose clip and disconnect the No. 1 turbo water hose from the No. 2 intercooler cooling water pipe.

    3. Slide the hose clip and disconnect the No. 1 sub-radiator hose from the No. 2 intercooler cooling water pipe.

    4. Remove the bolt and No. 2 intercooler cooling water pipe from the engine.

  35. REMOVE NO. 3 INTERCOOLER COOLING WATER PIPE


    1. Remove the clamp from the radiator reservoir bracket.

    2. B0058U2

      Remove the bolt and disconnect the ground wire from the No. 3 intercooler cooling water pipe.

    3. B00579FC02
      *1 No. 2 Turbo Water Hose
      *2 No. 4 Sub-radiator Hose
      *3 No. 5 Sub-radiator Hose

      Slide the hose clip and disconnect the No. 5 sub-radiator hose from the No. 2 water by-pass pipe.

    4. Slide the hose clip and disconnect the No. 2 turbo water hose from the No. 1 turbo water pipe sub-assembly.

    5. Slide the hose clip and disconnect the No. 4 sub-radiator hose from the No. 3 intercooler cooling water pipe.

    6. Remove the bolt and No. 3 intercooler cooling water pipe from the engine.

  36. DISCONNECT NO. 2 RADIATOR HOSE


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

  37. DISCONNECT NO. 1 RADIATOR HOSE


    1. Slide the hose clip and disconnect the No. 1 radiator hose from the cylinder head.

  38. REMOVE HEATER HOSE


    1. B0058YXC02
      *1 Outlet Water Hose Sub-assembly
      *2 Inlet Water Hose Sub-assembly
      *3 Outlet Water Hose
      *4 No. 5 Water By-pass Hose
      *5 No. 6 Water By-pass Hose

      Remove the heater hose from the engine.


      1. Slide the hose clamp and disconnect the inlet water hose sub-assembly from the heater core.

      2. Slide the hose clamp and disconnect the outlet water hose sub-assembly from the heater core.

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

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

      5. Slide the hose clip and disconnect the No. 6 water by-pass hose from the transmission oil cooler.

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

  39. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY (w/ Air Cooled Transmission Oil Cooler)


    1. B00588T

      Slide the 2 hose clips and disconnect the No. 1 transmission oil cooler hose assembly from the transmission oil cooler and automatic transaxle assembly.

  40. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

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  41. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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  42. DISCONNECT WIRE HARNESS


    1. B0057BX

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

    2. Remove the nut.

    3. Disconnect the 3 connectors, detach the 2 claws and disconnect the engine wire from the No. 1 relay block.

    4. B0058K1

      Disconnect the terminal from the No. 1 relay block side cover as shown in the illustration.

    5. B00599XC02
      *1 Engine Room Main Wire
      *2 Battery Current Sensor Connector
      *3 Ground Wire

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

    6. Disconnect the battery current sensor connector from the battery current sensor.

    7. Remove the bolt and disconnect the ground wire from the body.

  43. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. B005B4P

      Slide the hose clamp and disconnect the union to connector tube hose from the vacuum pump assembly.

  44. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B0057Z5C02
      *1 Fuel Tube Sub-assembly
      *2 No. 2 Fuel Tube Sub-assembly
      *3 Fuel Pipe Clamp

      Remove the fuel pipe clamp from the fuel tube sub-assembly and No. 2 fuel tube sub-assembly.

    2. Disconnect the fuel tube sub-assembly and No. 2 fuel tube sub-assembly from the 2 fuel pipes.

  45. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. B0058OB

      Slide the hose clamp and disconnect the fuel vapor feed hose assembly from the fuel pipe.

  46. REMOVE TRANSMISSION OIL COOLER

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  47. REMOVE STARTER ASSEMBLY


  48. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B005B1N

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

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

  49. REMOVE COLUMN HOLE COVER SILENCER SHEET

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  50. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  52. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  53. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  54. DISCONNECT FRONT SPEED SENSOR LH

    Click here

  55. DISCONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  56. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  57. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  58. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

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  59. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

  62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

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  63. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  64. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  65. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)

    Click here

  66. REMOVE FRONT EXHAUST PIPE SUB-ASSEMBLY

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

    Click here

  68. REMOVE FLYWHEEL HOUSING UNDER COVER

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  69. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

    Click here

  70. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. B005B3X

      Remove the 4 bolts and front suspension member reinforcement LH.

  71. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. B0058GE

      Remove the 4 bolts and front suspension member reinforcement RH.

  72. INSTALL ENGINE HANGER


    1. B0059YXC03
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with 3 bolts as shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-36100
      No. 2 Engine Hanger 12282-36100
      Bolt

      91552-81025

      91552-81050

  73. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B005AN6

      Remove the 6 bolts and front crossmember sub-assembly.

    2. B005796

      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. B0058ZV

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

    5. B00587A

      Remove the through bolt and nut, and disconnect the engine mounting insulator LH from the rear engine mounting bracket LH.

    6. B0059RU

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

    7. B0059DI

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

    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. B005ANI

      Remove the through bolt, nut 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.

  74. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY


    1. Set the height adjustment attachments and plate lift attachments, and then set the engine lifter to the automatic transaxle assembly.

      Note

      Using rope, attachments or equivalent tools, firmly secure the automatic transaxle assembly to the engine lifter.

    2. Remove the automatic transaxle assembly.


  75. REMOVE REAR ENGINE MOUNTING BRACKET

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  76. REMOVE TRANSFER ASSEMBLY (for AWD)

    Click here

  77. 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.

  78. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  79. 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 3 bolts, No. 1 engine hanger and No. 2 engine hanger.

  80. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B005AEU

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

  81. 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. B005BGEC01
      *1 Radiator Reservoir Bracket

      Remove the bolt and radiator reservoir bracket.

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

  82. REMOVE ENGINE MOUNTING SPACER

    Tech Tips

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


    1. B0058VQ

      Remove the 2 bolts and engine mounting spacer.

  83. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B005714C03
      *1 Bracket

      Remove the bolt and bracket.

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

  84. REMOVE DRIVE SHAFT BEARING BRACKET


    1. B0059QS

      Remove the 3 bolts and drive shaft bearing bracket from the cylinder block and stiffening crankcase assembly.