ENGINE ASSEMBLY REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge the fuel system pressure Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  3. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. A00O4RP

      Remove the 8 bolts and hood.

      Note

      If the hood support is detached from the ball joint, it become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  5. REMOVE FRONT BUMPER COVER LOWER


    1. Remove the clip, 5 bolts and front bumper cover lower.

  6. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A00O712

      Remove the 4 bolts.

    2. Unhook the engine under cover from the vehicle body as shown in the illustration.

  7. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  8. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


    1. Remove the 4 bolts and rear engine under cover.

  9. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  10. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    A009BWVE01
    Text in Illustration
    *1 Reservoir Cap *2 Radiator Cap
    *3 Cylinder Block Drain Cock Plug *4 Radiator Drain Cock Plug

    1. A009960E02
      Text in Illustration
      *1 Vinyl Hose

      Install a vinyl hose to the radiator side.

    2. A0097IAE02
      Text in Illustration
      *1 Vinyl Hose

      Install a vinyl hose to the engine side.

    3. Loosen the radiator drain cock plug.

    4. Remove the radiator cap and drain the coolant.

      Tech Tips

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

    5. Loosen the cylinder block drain cock plug and drain the coolant from the engine.

  11. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

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

  12. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


    1. Remove the drain plug and gasket, and drain ATF.

    2. Install a new gasket and the drain plug.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A00O61B

      Detach the 3 clamps and disconnect the mass air flow meter connector.

    2. Remove the bolt, detach the clamp and disconnect the ground wire.

    3. A00O34B

      Detach the 4 clamps.

    4. Loosen the hose clamp and remove the air cleaner cap.

  14. REMOVE AIR CLEANER CASE


    1. A00O7OB

      Remove the air cleaner filter element.

    2. Remove the 3 bolts and air cleaner case.

  15. REMOVE INTAKE AIR CONNECTOR


    1. A00XEFB

      w/ Manifold absolute pressure sensor:


      1. Disconnect the air pressure sensor connector.

      2. Detach the 2 clamps.

      3. Disconnect the vacuum hose.

    2. A00XHJU

      Disconnect the No. 2 ventilation hose.

    3. Detach the wire harness clamp.

    4. A00XD8ME01

      Disconnect the vacuum hose.

    5. A00XGAC

      Loosen the hose clamp.

    6. Remove the 3 bolts and intake air connector.

  16. REMOVE NO. 1 AIR INJECTION SYSTEM HOSE


    1. A00O6SF

      Remove the hose clamp.

      Note

      Do not reuse the hose clamp.

    2. Using needle-nose pliers, grip the claws of the clamps and slide the clamps to remove the air injection system hose.

  17. REMOVE RADIATOR RESERVOIR


    1. A00975M

      Disconnect the reservoir hose from the radiator.

    2. Remove the 3 bolts and radiator reservoir.

  18. REMOVE NO. 1 RADIATOR HOSE


    1. Using needle-nose pliers, grip the claws of the clamps and slide the clamps to remove the radiator hose.

  19. REMOVE NO. 2 RADIATOR HOSE


    1. Using needle-nose pliers, grip the claws of the clamps and slide the clamps to remove the radiator hose.

  20. REMOVE FAN SHROUD


    1. A0096VT

      Detach the claw to open the flexible hose clamp.

    2. A0095ZI

      Loosen the 4 nuts holding the fluid coupling fan.

    3. Remove the fan and generator V-belt Click here.

    4. A0096JP

      Remove the 2 bolts holding the fan shroud.

    5. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

  21. REMOVE NO. 1 OIL COOLER INLET HOSE AND NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

    A0095HME01

    1. Disconnect the No. 1 oil cooler inlet hose and No. 1 oil cooler outlet hose from the No. 2 oil cooler tube.

    2. Disconnect the 2 hoses from the oil cooler inlet tube and No. 1 oil cooler outlet tube and remove them.

      Note

      When disconnecting the hoses from the tube, support the tube by hand and be careful to prevent the tube from being deformed.

  22. REMOVE FUEL HOSE


    1. A00OAMW

      Detach the 2 clamps.

    2. Remove the fuel hose Click here.

  23. REMOVE NO. 2 FUEL HOSE


    1. A00O4WL

      Disconnect the fuel hose from the clamp.

    2. Using needle-nose pliers, grip the claws of the clamps and slide the clamps to remove the fuel hose.

  24. DISCONNECT PURGE LINE HOSE


    1. A00O3NR

      Disconnect the purge line hose from the vacuum switching valve.

  25. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A00O7GF

      Using needle-nose pliers, grip the claws of the clamp and slide the clamp to disconnect the check valve hose.

  26. DISCONNECT HEATER HOSE


    1. A00OA8B

      Disconnect the 2 heater water hoses.

  27. DISCONNECT VANE PUMP ASSEMBLY


    1. A00OACH

      Remove the bolt and disconnect the pressure feed tube.

    2. A00O71E

      Disconnect the 2 connectors.

    3. Remove the 2 bolts and disconnect the vane pump.

      Tech Tips

      It is not necessary to completely remove the vane pump. With the hoses connected to the vane pump, hang the vane pump on the vehicle body with a rope.

  28. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. A00O4YU

      Remove the bolt and disconnect the suction hose from the engine.

    2. A00O7MQ

      Disconnect the connector.

    3. Remove the 4 bolts and disconnect the cooler compressor.

      Tech Tips

      It is not necessary to completely remove the cooler compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  29. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. A00XIZL

      Remove the 5 clips and front No. 1 fender apron to frame seal.

  30. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL LH

    A00JVYM

    1. Remove the 5 clips and front fender apron to frame seal.

  31. DISCONNECT ENGINE WIRE


    1. A00O5QM

      Detach the 3 clamps and disconnect the engine wire from the vehicle RH side.

    2. Disconnect the ECM connector.


      1. Remove the glove compartment door Click here.

      2. A00OAG6

        Detach the clamp and disconnect the 9 connectors.

      3. A00O4E5

        Detach the clamp.

      4. A00O549

        Detach the grommet from the wire harness support.

      5. A00O7MB

        Detach the 4 claws to remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

    3. A00O3JU

      Disconnect the connector and detach the clamp.

    4. Remove the nut from the engine room No. 1 relay block.

    5. Detach the 2 clamps and disconnect the wire harness from the engine room No. 1 relay block.

    6. A00O95V

      Detach the 2 clamps.

    7. Remove the bolt and disconnect the ground wire.

    8. A00O4ZA

      Remove the bolt and bracket from the engine mounting bracket LH.

  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

    2. Disconnect the heated oxygen sensor connector and detach the wire harness clamp.

    3. for 3 Door:

      Remove the 4 bolts and 2 compression springs.

    4. for 5 Door:

      Remove the 4 bolts and 4 compression springs.

    5. Remove the front exhaust pipe from the pipe support.

    6. Remove the 2 gaskets.

  33. REMOVE MANIFOLD STAY

    A00XGZ2

    1. Remove the 3 bolts and manifold stay.

  34. REMOVE PROPELLER SHAFT ASSEMBLY


    1. A00XDCAE01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    2. Remove the 4 nuts and 4 washers.

    3. A00XGPFE01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential flange.

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. Remove the propeller shaft.

  35. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. A00XDITE07
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential.

    2. Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly.

    3. A00XGE4E10
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    4. Remove the 4 nuts, 4 washers and front propeller shaft assembly.

  36. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)


    1. Remove the flywheel housing dust seal.

    2. A00O3P9

      Turn the crankshaft to gain access to the 6 bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

  37. REMOVE STARTER ASSEMBLY


    1. for 1.4 kW Type:

      Remove the starter assembly Click here.

    2. for 2.0 kW Type:

      Remove the starter assembly Click here.

  38. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Remove the automatic transmission assembly Click here.

  39. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Remove the manual transmission assembly Click here.

  40. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. for Automatic Transmission:


      1. A00O4V1

        Remove the 4 bolts of the rear engine mounting insulator.

      2. A00O5C5

        Remove the bolt and rear engine mounting heat insulator.

      3. Remove the 4 bolts and engine mounting insulator from the transmission.

    2. for Manual Transmission:


      1. A00O744

        Remove the 4 bolts of the rear engine mounting insulator.

      2. A00O36Q

        Remove the bolt and rear engine mounting heat insulator.

      3. Remove the 4 bolts and engine mounting insulator from the transmission.

  41. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. A00K1F9E01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00K12M

      Remove the 10 bolts, rear drive plate spacer, drive plate and front drive plate spacer.

  42. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A00O3X4E01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  43. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note

    Keep the lining part of the clutch disc, the pressure plate and the surface of the flywheel away from oil and foreign matter.

  44. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. A00K1F9E01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00JYVU

      Remove the 10 bolts and flywheel.

  45. REMOVE REAR END PLATE


    1. Detach the flywheel housing dust seal.

    2. Remove the 2 bolts and rear end plate.

  46. INSTALL NO. 1 ENGINE HANGER


    1. A00O888E01
      Text in Illustration
      *a LH Side
      *b RH Side

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-75040
      Bolt 91552-A1020

  47. REMOVE ENGINE ASSEMBLY


    1. Attach an engine sling device and hang the engine with a chain block.

      Note

      Pay attention to the angle of the sling device as the engine assembly or engine hanger may be damaged or deformed if the angle is incorrect.

    2. A00O45FE01
      Text in Illustration
      *a RH Side
      *b LH Side

      Remove the 4 engine mounting insulator bolts and nuts.

    3. Lift the engine out from the vehicle slowly and carefully.

      Note

      Make sure the engine is clear of all wiring, hoses and cables.

  48. INSTALL ENGINE TO ENGINE STAND


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

    2. Remove the 2 bolts and 2 engine hangers.