ENGINE ASSEMBLY REMOVAL

  1. PRECAUTION

    CAUTION:

    The engine assembly with transmission 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 Click here.

  2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM

    1. Turn the A/C switch on.

    2. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.

    3. Turn the ignition switch off.

    4. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  6. REMOVE FRONT WHEELS

  7. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

  8. REMOVE ENGINE UNDER COVER RH

  9. REMOVE FRONT FENDER APRON SEAL RH

  10. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

  11. REMOVE ENGINE UNDER COVER LH

  12. REMOVE FRONT FENDER APRON SEAL LH

  13. DRAIN ENGINE OIL

    1. Remove the oil filler cap.

    2. Remove the oil drain plug and drain the oil into a container.

    3. Clean the oil drain plug.

    4. Install the oil drain plug with a new gasket.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  14. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    1. Loosen the radiator drain cock plug.

    2. Loosen the 2 cylinder block drain cock plugs.

    3. Remove the radiator cap sub-assembly.

      A011TE6E01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Cylinder Block Drain Cock Plug
      *3 Radiator Drain Cock Plug *4 Air Drain Cock Plug

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

  15. DRAIN AUTOMATIC TRANSAXLE FLUID

    1. Remove the front wheel opening extension pad LH, engine under cover LH and front fender apron seal LH.

    2. Remove the refill plug and gasket from the automatic transaxle.

      A011U0Y

    3. Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transaxle.

      A011TO6

    4. Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle.

      A011SMOE04
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube
      *2 Hexagon Socket Wrench
      *a Overflow Plug Hole

    5. Drain automatic transaxle fluid from the automatic transaxle.

    6. Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle.

      A011SMOE04
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube
      *2 Hexagon Socket Wrench
      *a Overflow Plug Hole
      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }

    7. Using a 6 mm hexagon socket wrench, install a new gasket and the overflow plug to the automatic transaxle.

      A011TO6
      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    8. Temporarily install the gasket and refill plug to the automatic transaxle.

      A011U0Y

  16. REMOVE COOL AIR INTAKE DUCT SEAL

    1. Remove the 7 clips and cool air intake duct seal.

      A011RCO

  17. REMOVE V-BANK COVER SUB-ASSEMBLY

    1. Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      A011RX1

      Note

      Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

  18. REMOVE INLET NO. 2 AIR CLEANER

    1. Disconnect the 2 wire harness clamps and vacuum hose clamp.

      A011SYZ

    2. Remove the 2 bolts and inlet No. 2 air cleaner.

  19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    1. Disconnect the mass air flow meter connector and wire harness clamp.

      A011U6Z

    2. Disconnect the 3 hoses.

      A011UDY

    3. Separate the ventilation hose.

    4. Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly.

      A011V2M

    5. Release the 2 clamps and remove the air cleaner cap with hose.

  20. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    1. Disconnect the wire harness clamp, connector, vacuum hose and No. 1 fuel vapor feed hose.

      A011S1P

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

  22. REMOVE BATTERY

    1. Disconnect the positive (+) cable from the positive (+) battery terminal.

      A011SDV

    2. Loosen the nut and remove the bolt.

    3. Remove the battery and battery tray.

  23. REMOVE INLET NO. 1 AIR CLEANER

    1. Disengage the pin and remove the inlet No. 1 air cleaner.

      A011SXU

  24. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY

    1. Disengage the claw and disconnect the 2 vacuum hoses.

      A011QY1

    2. Remove the 2 bolts and intake air resonator sub-assembly.

  25. REMOVE NO. 2 ENGINE MOUNTING STAY RH

    1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

      A011UZO

  26. REMOVE ENGINE MOVING CONTROL ROD BRACKET

    1. Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.

      A011QV4

  27. REMOVE ENGINE MOVING CONTROL ROD

    1. Remove the bolt and engine moving control rod from the engine moving control rod bracket.

      A011RVQ

      Tech Tips

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  28. SEPARATE EARTH WIRE

    1. Remove the 2 bolts and separate the earth wire from the engine assembly.

      A011UIG

  29. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

    1. Disconnect the No. 1 fuel vapor feed hose.

      A011U1A

  30. DISCONNECT UNION TO CHECK VALVE HOSE

    1. Disconnect the union to check valve hose from the brake booster.

      A011TWD

  31. DISCONNECT INLET RADIATOR HOSE

    1. Remove the hose clamp to separate the air fuel ratio sensor wire from the inlet radiator hose.

      A011UVV

    2. Remove the hose clamp to separate the No. 3 water by-pass hose from the inlet radiator hose.

    3. Disconnect the inlet radiator hose.

  32. DISCONNECT OUTLET RADIATOR HOSE

    1. Disconnect the outlet radiator hose.

      A011RT0

  33. DISCONNECT NO. 3 WATER BY-PASS HOSE

    1. Disconnect the No. 3 water by-pass hose from the transmission oil cooler.

      A011REF

  34. DISCONNECT INLET HEATER WATER HOSE

    1. Disconnect the inlet heater water hose.

      A011RVY

  35. DISCONNECT WATER HOSE SUB-ASSEMBLY

    1. Disconnect the water hose sub-assembly.

      A011QXR

  36. REMOVE STARTER ASSEMBLY

    1. Disconnect the starter connector.

      A011R5Y

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the starter wire.

    4. Remove the 2 bolts and starter.

      A011R3U

  37. DISCONNECT ENGINE WIRE

    1. Remove the No. 1 relay block cover.

    2. Remove the 2 nuts and disconnect the wire clamp.

      A011UVP

    3. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

    4. Disconnect the 4 connectors.

      A011T03

    5. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

    6. Pull up the lever to disconnect the ECM connector.

      A011UMD

    7. Disconnect the 2 wire clamps.

  38. REMOVE AIR CLEANER BRACKET

    1. Disconnect the 2 wire clamps.

      A011TF8

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

  39. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    1. Move the shift lever to N.

    2. Disconnect the wire harness clamp.

      A011TM4

    3. Remove the nut from the control shaft lever.

      A011RPT

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

  40. DISCONNECT FUEL MAIN TUBE

    1. Remove the No. 1 fuel pipe clamp.

      A011UNI

    2. Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.

      A011SP8
      Text in Illustration
      A011T1X Push
      A011V7Q Pull

      Note

      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

  41. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    1. Disconnect the 3 connectors.

      A011T4M

    2. Disengage the 2 clamps.

    3. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor and magnetic clutch.

      A011TYB

    4. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  42. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    1. Remove the bolt and disconnect the suction hose sub-assembly from the compressor and magnetic clutch.

      A011V5X

    2. Remove the O-ring from the suction hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  43. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

    1. Remove the 2 nuts and No. 1 exhaust pipe support bracket (for Front Side).

      A011V84

  44. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. Disconnect the 2 wire harnesses from the clamp.

      A011RQI

    2. Disconnect the 2 heated oxygen sensor connectors.

    3. Remove the 2 bolts and No. 1 exhaust pipe support bracket (for Rear Side).

      A011UQE

    4. Remove the 4 bolts, 4 nuts and front exhaust pipe assembly.

      A011T58

    5. Remove the 3 gaskets from the front exhaust pipe assembly.

  45. SECURE STEERING WHEEL

    1. Secure the steering wheel with the seat belt in order to prevent rotation.

      A011S81

      Tech Tips

      This operation is useful to prevent damage to the spiral cable.

  46. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    1. Put matchmarks on the steering intermediate shaft assembly and steering link assembly.

      A011T57E02
      Text in Illustration
      *a Matchmark

    2. Remove the bolt.

    3. Separate the steering intermediate shaft assembly from the steering link assembly.

  47. REMOVE FRONT AXLE SHAFT NUT LH

    1. Using SST and a hammer, release the staked part of the front axle shaft nut.

      A011RJ1E01
      SST
      09930-00010

      Note

      Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle shaft nut.

  48. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  49. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    1. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.

      A011S3W

      If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

  50. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  51. SEPARATE FRONT SPEED SENSOR LH

    1. Remove the bolt, disengage the clamp and separate the front speed sensor and front flexible hose.

      A011T8Z

      Note

      Be sure to separate the front speed sensor from the front shock absorber completely.

    2. Remove the bolt and front speed sensor from the steering knuckle.

      A011UA6

      Note

      • Prevent foreign matter from contacting the sensor tip.

      • Be careful not to damage the front speed sensor.

      • Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.

  52. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  53. SEPARATE TIE ROD ASSEMBLY LH

    1. Remove the cotter pin and nut.

      A011UM3

    2. Install SST to the tie rod assembly LH.

      A011TI2E01
      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure that the lower ends of the tie rod assembly LH and SST are aligned.

    3. Secure SST using a string.

      Note

      Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.

    4. Using SST, separate the tie rod assembly LH from the steering knuckle.

      A011UQUE02
      Text in Illustration
      *1 Center Nut - -
      *a String *b Grease Application Area
      A011V7Q Place the wrench here. - -
      SST
      09960-20010   ( 09961-02010 )

      CAUTION:

      Apply grease to the bolt threads and the tip of SST.

      Note

      • Install SST with the center nut so that A and B shown in the illustration are parallel. Otherwise, the dust cover may be damaged.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the front disc brake dust cover.

      • Do not damage the ball joint dust cover.

      • Do not damage the steering knuckle.

  54. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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

    1. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.

      A011S5I

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

    Tech Tips

    Perform the same procedure as for the LH side.

  57. SEPARATE FRONT DRIVE SHAFT ASSEMBLY

    1. Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.

      A011V80E01
      Text in Illustration
      *a Matchmark

    2. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.

      If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer.

  58. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    1. Using SST, remove the front drive shaft assembly LH.

      A011RALE01
      SST
      09520-00031
      09520-01010

      Note

      • Do not damage the transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • Do not drop the front drive shaft assembly LH.

  59. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    1. Using a screwdriver, remove the front drive shaft hole snap ring LH.

      A011QTP

  60. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    1. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

      A011QR7

    2. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.

      Note

      • Do not damage the front transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • Do not drop the front drive shaft assembly RH.

    3. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH.

  61. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

    1. Remove the bolt and No. 1 exhaust pipe support bracket.

      A011RO0

  62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    1. Remove the 2 bolts and No. 1 exhaust pipe support bracket sub-assembly.

      A011TGW

  63. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    1. Turn the crankshaft to gain access to the removable locations of the 6 torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

      A011T1Q

      Tech Tips

      There will be one black colored bolt.

  64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. Set the engine lifter.

      A011ST4
      Text in Illustration
      A011TKF Attachment Installation Position

      Note

      • Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.

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

      • 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. Remove the 4 bolts, 2 nuts and frame side rail plates RH and LH.

      A011QZL

    3. Remove the 4 bolts, 2 nuts and front suspension member rear braces RH and LH.

    4. Operate the engine lifter, then remove the engine assembly 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.

    5. Install the engine hangers Click here.

  65. REMOVE V-RIBBED BELT

    1. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and remove the V-ribbed belt from the V-ribbed belt tensioner.

      A011QOJ

    2. While turning the V-ribbed belt tensioner counterclockwise, align its holes, and then insert a 5 mm hexagon wrench into the holes to fix the V-ribbed belt tensioner.

  66. REMOVE GENERATOR ASSEMBLY

    1. Remove the terminal cap.

      A011T2Z

    2. Remove the nut and disconnect the wire harness from terminal B.

    3. Disconnect the generator connector from the generator assembly.

    4. Remove the bolt and disconnect the wire harness clamp.

    5. Remove the 2 bolts.

      A011RS8

    6. Remove the 2 bolts and generator assembly.

      A011TY6

    7. Disconnect the wire harness clamp and remove the generator bracket.

  67. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

    A011R0E

    1. Remove the 4 bolts and compressor and magnetic clutch and bracket.

  68. REMOVE TRANSMISSION OIL COOLER

    1. Disconnect the breather plug and remove the clamp.

      A011S3R

    2. Remove the No. 4 water by-pass hose.

    3. Remove the No. 1 oil cooler outlet hose and No. 1 oil cooler inlet hose.

      A011SVNE01
      Text in Illustration
      *1 No. 1 Oil Cooler Outlet Hose
      *2 No. 1 Oil Cooler Inlet Hose

    4. Remove the 2 bolts and transmission oil cooler with the transmission oil cooler stay from the automatic transaxle assembly.

      A011QN3

  69. REMOVE FRONT FRAME ASSEMBLY

    1. Disconnect the oil pressure switch connector and 2 clamps.

      A011RW0

    2. Disconnect the 2 clamps and vacuum switching valve connector.

      A011S68

    3. Remove the bolt and disconnect the front engine mounting insulator.

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

      A011RRP

    5. Remove the nut and disconnect the engine mounting insulator RH.

      A011SA9

    6. Remove the front frame assembly.

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

    1. Remove the 3 nuts and front engine mounting insulator assembly.

      A011RQL

      Tech Tips

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

  71. REMOVE ENGINE MOUNTING INSULATOR LH

    1. Remove the 2 hole plugs from the front frame assembly.

      A011UY2

    2. Remove the 3 nuts and engine mounting insulator LH.

      Tech Tips

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

  72. REMOVE ENGINE MOUNTING INSULATOR RH

    1. Remove the 2 hole plugs from the front frame assembly.

      A011UOO

    2. Remove the 3 nuts and engine mounting insulator RH.

      Tech Tips

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

  73. REMOVE ENGINE WIRE

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

  74. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

    1. Using the transmission jack attachment, set the automatic transaxle assembly on a transmission jack.

      Note

      • Secure the automatic transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.

      • To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the automatic transaxle assembly.

      • Hold the engine assembly with a suitable adapter, such as a rope, during the operation.

    2. Remove the 11 bolts and transaxle.

      A011R8U

      Note

      To prevent damage to the knock pins, do not pry between the transaxle and engine.

  75. REMOVE ENGINE MOUNTING BRACKET RH

    1. Remove the 3 bolts and engine mounting bracket RH.

      A011V5Y

  76. REMOVE DRIVE SHAFT BEARING BRACKET

    1. Remove the 3 bolts and drive shaft bearing bracket.

      A011SY9

  77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    1. Using SST, hold the crankshaft pulley.

      A011TDEE01
      SST
      09213-70011   ( 09213-70020 )
      09330-00021

    2. Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer.

      A011QSI

  78. INSTALL ENGINE ON ENGINE STAND

    1. Install the engine onto an engine stand with the bolts.