ENGINE ASSEMBLY REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

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

  5. REMOVE FRONT WHEEL

  6. REMOVE NO. 1 ENGINE UNDER COVER

  7. REMOVE ENGINE UNDER COVER

  8. REMOVE NO. 2 ENGINE UNDER COVER (for Front Side)

  9. REMOVE NO. 2 ENGINE UNDER COVER (for Rear Side)

  10. REMOVE REAR ENGINE UNDER COVER LH

  11. REMOVE REAR ENGINE UNDER COVER RH

  12. 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 }

  13. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. A01CD8ME01
      Text in Illustration
      *1 No. 1 Engine Under Cover
      *a Hose

      Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.

    2. Loosen the radiator drain cock plug.

    3. Remove the reserve tank cap. Then drain the engine coolant.

    4. Loosen the cylinder block drain cock plug (for Bank 1).

    5. Loosen the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

      A01CDICE01
      Text in Illustration
      *1 Radiator Reserve Tank *2 Reserve Tank Cap
      *3 Radiator Drain Cock Plug *4 Air Drain Cock Plug
      *5 Cylinder Block Drain Cock Plug (for Bank 1) *6 Cylinder Block Drain Cock Plug (for Bank 2, w/ Cylinder Block Drain Cock Plug)

      Tech Tips

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

    6. Disconnect a hose with an inside diameter of 9 mm (0.354 in.) from the radiator drain cock.

  14. DRAIN AUTOMATIC TRANSAXLE FLUID


    1. Remove the 5 clips and rear engine under cover LH.

    2. A01CEJG

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

    3. A01CCOF

      Remove the refill plug and gasket from the automatic transaxle.

    4. A01CEFPE02

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

    5. Drain automatic transaxle fluid from the automatic transaxle.

    6. A01CEFPE02

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

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    7. A01CEJG

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

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    8. A01CCOF

      Install a new gasket and the refill plug to the automatic transaxle.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  15. REMOVE COWL SIDE TRIM BOARD RH (for RHD)


    1. A01CFL6

      Remove the clip.

    2. Disengage the clip, claw and 2 guides, and remove the cowl side trim board RH.

  16. REMOVE COWL SIDE TRIM BOARD LH (for LHD)


    1. A01CCIK

      Remove the clip(A).

    2. Disengage the clip, claw and 2 guides, and remove the cowl side trim board LH.

  17. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (for RHD)


    1. A01CFFK

      Remove the 2 screws <B>.

    2. Disengage the 2 claws and 2 guides.

    3. A01CE9QE01

      Disengage the 2 claws and disconnect the DLC3.

    4. Disengage the clamp.

    5. Disconnect each connector and remove the No. 1 instrument panel under cover sub-assembly.

  18. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (for LHD)


    1. A01CCYO

      Remove the 2 screws <B>.

    2. Disengage the 2 claws and guide.

    3. Disengage the clamp.

    4. Disconnect each connector and remove the No. 1 instrument panel under cover sub-assembly.

  19. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (for RHD)


    1. A01CC18

      Disengage the 3 claws and disconnect the hood lock control cable assembly.

    2. A01CC11

      Disengage the 3 claws and disconnect the fuel lid lock control cable assembly.

    3. A01CCKN

      Remove the 3 screws <B>.

    4. Disengage the 14 claws and the 3 guides, and remove the lower instrument panel finish panel as shown in the illustration.

      A01CCUJ

      Note


      • Make sure to follow the order shown in the illustration to avoid damage to the lower instrument panel finish panel.

      • While supporting the knee airbag, remove the lower instrument panel finish panel.

  20. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (for LHD)


    1. A01CF0E

      Disengage the 3 claws and disconnect the hood lock control cable assembly.

    2. A01CCXK

      Disengage the 3 claws and disconnect the fuel lid lock control cable assembly.

    3. A01CGDM

      Disconnect the fuel filler opening lid lock sub-assembly and remove the fuel lid lock open lever sub-assembly.

    4. A01CCWL

      Remove the 3 screws <B>.

    5. Disengage the 13 claws, clip and the 3 guides and remove the lower instrument panel finish panel as shown in the illustration.

      A01CECJ

      Note


      • Make sure to follow the order shown in the illustration to avoid damage to the lower instrument panel finish panel.

      • While supporting the knee airbag, remove the lower instrument panel finish panel.

  21. REMOVE CENTER FLOOR CARPET COVER RH (for RHD)


    1. A01CDKB

      Using a clip remover, remove the 2 clips.

    2. A01CFS0E01

      Disengage the 4 claws and remove the center floor carpet cover RH in the order shown in the illustration.

      Tech Tips

      Remove the center floor carpet cover RH while pushing on the instrument cluster finish panel.

  22. REMOVE CENTER FLOOR CARPET COVER RH (for LHD)


    1. A01CBO2

      Using a clip remover, remove the clip.

    2. A01CB02E01

      Disengage the 5 claws and remove the center floor carpet cover RH in the order shown in the illustration.

      Tech Tips

      Remove the center floor carpet cover RH while pushing on the instrument cluster finish panel.

  23. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY


    1. A01CC1ZE01

      Disengage the claw and release the glove compartment door stopper.

    2. Slightly bend stoppers (A) and (B) in the directions indicated by the arrows in the illustration and pull the glove compartment door assembly until the stoppers are released.

    3. A01CFV2E01

      Open the glove compartment door assembly to approximately 55° from its closed position. Pull it horizontally toward the rear of the vehicle to disengage the 2 hinges and remove the glove compartment door assembly.

      Note

      Pulling the glove compartment door assembly upward to remove it causes the hinges to deform. Be sure to pull out the glove compartment door assembly horizontally.

  24. REMOVE CENTER FLOOR CARPET COVER LH


    1. A01CG2A

      Using a clip remover, remove the clip.

    2. A01CF5YE01

      Disengage the 4 claws and remove the center floor carpet cover LH in the order shown in the illustration.

      Tech Tips

      Remove the center floor carpet cover LH while pushing on the instrument cluster finish panel.

  25. REMOVE INSTRUMENT PANEL BOX ASSEMBLY


    1. A01CD20E01

      Slightly bend stoppers (A) and (B) in the directions indicated by the arrows in the illustration and pull the instrument panel box assembly until the stoppers are released.

    2. A01CGCYE01

      Open the instrument panel box assembly to approximately 60° from its closed position. Pull it horizontally toward the rear of the vehicle to disengage the 2 hinges and remove the instrument panel box assembly.

      Note

      Pulling the instrument panel box assembly upward to remove it causes the hinges to deform. Be sure to pull out the instrument panel box horizontally.

  26. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY


    1. A01CFL8

      Remove the bolt <C>.

    2. Disengage the 12 claws.

      Tech Tips

      First disengage the 6 claws for the right side and then pull the panel to the rear of the vehicle to disengage the 6 claws for the left side.

    3. A01CD3Y

      Disengage the 3 claws.

    4. Disconnect each connector and remove the instrument cluster finish panel assembly.

  27. DISCONNECT OXYGEN SENSOR CONNECTOR (for Bank 1 Sensor 2)


    1. A01CFGU

      Disconnect the oxygen sensor connector (for Bank 1 Sensor 2).

    2. A01CFA6

      Remove the grommet.

  28. REMOVE WINDSHIELD WIPER ARM COVER


    1. A01CBB7E01

      Using a screwdriver, disengage the 2 claws and remove the 2 windshield wiper arm covers.

      Tech Tips

      Tape the screwdriver tip before use.

  29. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A01CEJI

      Remove the nut and the front wiper arm and blade assembly RH.

  30. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A01CB95

      Remove the nut and the front wiper arm and blade assembly LH.

  31. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01CFAO

      Remove the 2 clips.

    2. A01CBJT

      Disengage the 15 claws and 2 guides, and remove the cowl top ventilator louver sub-assembly as shown in the illustration.

  32. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01CAUN

      Disconnect the connector.

    2. A01CDAS

      Remove the 3 bolts and the windshield wiper motor and link assembly as shown in the illustration.

  33. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A01CBAK

      Remove the 2 nuts and separate the brake master cylinder reservoir with bracket from the outer cowl top panel.

  34. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01CED5

      Apply protective tape as shown in the illustration.

      Text in Illustration
      A01CC81 Protective Tape
    2. A01CCFB

      Disconnect the 2 clamps from the outer cowl top panel.

    3. Remove the 8 bolts.

    4. A01CDT7

      Remove the outer cowl top panel as shown in the illustration.

  35. REMOVE RADIATOR COVER SUB-ASSEMBLY (for ALPHARD)


    1. A01CDEV

      Using a clip remover, remove the 4 clips and radiator cover sub-assembly.

  36. REMOVE RADIATOR COVER SUB-ASSEMBLY (for VELLFIRE)


    1. A01CEUO

      Using a clip remover, remove the 4 clips and radiator cover sub-assembly.

  37. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01CCP4

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

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  38. REMOVE BATTERY


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

    2. A01CDEA

      Disconnect the 2 wire clamps.

    3. Loosen the nut, and remove the bolt with the battery clamp.

    4. Remove the battery, battery insulator and battery tray.

  39. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01CBVZE01

      Separate the mass air flow meter connector and 2 wire harness clamps.

    2. Separate the purge line hose.

    3. A01CAN5

      Separate the ventilation hose.

    4. Loosen the hose clamp and separate the air cleaner hose from the throttle body.

    5. A01CB66

      Release the 2 clamps and remove the air cleaner cap sub-assembly.

  40. REMOVE AIR CLEANER CASE


    1. Remove the air cleaner filter element.

    2. A01CFWV

      Disconnect the wire clamp.

    3. Remove the 3 bolts and air cleaner case.

  41. REMOVE NO. 2 AIR CLEANER INLET


    1. A01CBBU

      Remove the bolt and No. 2 air cleaner inlet.

  42. REMOVE BATTERY CARRIER


    1. A01CF18

      Disconnect the 2 wire clamps.

    2. Remove the 4 bolts and battery carrier.

  43. REMOVE BATTERY CARRIER SUPPORT


    1. A01CAMZ

      Remove the 2 bolts and battery carrier support.

  44. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY


    1. A01CE9A

      Disconnect the No. 1 and No. 2 water by-pass hoses.

    2. Remove the bolt and radiator reservoir tank assembly.

  45. REMOVE RADIATOR RESERVOIR TANK BRACKET


    1. A01CEDK

      Remove the 2 bolts and radiator reservoir tank bracket.

  46. DISCONNECT OIL COOLER HOSE


    1. A01CBXO

      Disconnect the 2 oil cooler hoses.

  47. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01CDC4E01

      Disconnect the No. 1 radiator hose.

  48. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01CD0Q

      Disconnect the No. 2 radiator hose.

  49. DISCONNECT HEATER WATER INLET HOSE


    1. A01CD14

      Disconnect the heater water inlet hose.

  50. DISCONNECT HEATER WATER OUTLET HOSE


    1. A01CATT

      Disconnect the heater water outlet hose.

  51. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A01CD56

      Disconnect the No. 1 fuel vapor feed hose.

  52. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A01CDN3

      Disconnect the union to connector tube hose.

  53. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01CCF5

      Remove the clip and nut, and separate the transmission control cable assembly from the transaxle.

  54. REMOVE ECM


    1. A01CCDQ

      Separate the wire harness clamp.

    2. Remove the 3 bolts and separate the ECM with brackets.

    3. A01CDXFE01

      Disconnect the 2 ECM connectors and remove the ECM with brackets.

      Note

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


      1. Push in the locks on the 2 levers, raise the levers, and disconnect the 2 ECM connectors.

    4. A01CCPS

      Remove the 4 screws and 2 ECM brackets.

  55. DISCONNECT ENGINE WIRE


    1. Remove the engine room relay block cover.

    2. A01CAOE

      Disconnect the 2 connectors.

    3. Using a screwdriver, unlock the 2 claws and separate the engine wire from the engine room relay block.

    4. A01CD4B

      Using a screwdriver, unlock the 2 claws and loosen the bolt.

    5. A01CB2B

      Slide the battery positive (+) cable as shown in the illustration.

    6. A01CBKG

      Remove the bolt and 3 clamps, and separate the wire harness protector from the bracket.

    7. A01CCOZ

      Remove the bolt and clamp, and separate the ground cable from the body.

    8. A01CG3E

      Disconnect the clamp, remove the nut, and disconnect the battery positive (+) cable.

    9. Disconnect the clamp, remove the bolt, and disconnect the ground cable.

    10. A01CAN2

      Disconnect the connector, remove the bolt, and disconnect the ground cable.

  56. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01CAQB

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

  57. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01CAUE

      Remove the nut and disconnect the No. 1 cooler refrigerant discharge hose.

      Note

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

  58. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. Disconnect the clamp.

    2. Remove the nut and disconnect the No. 1 cooler refrigerant suction hose.

      Note

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

  59. DISCONNECT FUEL MAIN TUBE


    1. A01CEU5E01

      Disengage the claw and open the No. 1 EFI fuel pipe clamp cover.

      Tech Tips

      Do not remove the No. 1 EFI fuel pipe clamp from the pipe.

    2. Pinch the fuel tube connector and then pull out the fuel main tube.

      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.

  60. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for Front Side)


    1. A01CDW3

      Remove the 4 bolts, 2 nuts, 2 compression springs and center exhaust pipe assembly (for Front Side).

    2. Remove the 3 gaskets from the center exhaust pipe assembly (for Front Side).

  61. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01CD1Q

      Disconnect the No. 2 oxygen sensor connector (for Bank 2).

    2. A01CDM6

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

    3. Remove the 2 nuts and front exhaust pipe assembly.

    4. Remove the gasket from the front exhaust pipe assembly.

  62. SECURE STEERING WHEEL


    1. A01CEX4

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

      Tech Tips

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

  63. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A01CEG5

      Remove the 2 clips and column hole cover silencer sheet.

  64. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01CGGA

      Remove the bolt from the No. 2 steering intermediate shaft assembly.

    2. Slide the No. 2 steering intermediate shaft assembly toward the steering column assembly.

      Note

      Do not separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft assembly.

    3. A01CAW8E01

      Put matchmarks on the No. 2 steering intermediate shaft assembly and the steering intermediate shaft assembly.

    4. Separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft assembly.

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


    1. A01CET6E01

      Push clip B towards center of the hole to release it, then push on clip A and remove the No. 1 steering column hole cover sub-assembly from the body.

      Note

      Do not damage clip A and B.

  66. REMOVE FRONT AXLE SHAFT NUT LH


    1. A01CG4WE01

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

      SST
      09930-00010

      Note


      • Insert SST into the groove with the flat surface facing up.

      • Do not damage the tip of SST using a grinder.

      • Completely unstake the staked part before removing the front axle shaft nut.

      • Do not damage the threads of the drive shaft.

    2. Using a socket wrench (30 mm), remove the front axle shaft nut.

  67. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  68. SEPARATE FRONT SPEED SENSOR LH


    1. A01CCEP

      Remove the 2 bolts and separate the front flexible hose and the front speed sensor from the front shock absorber and steering knuckle.

    2. A01CBSW

      Remove the bolt and clamp to separate the front speed sensor from the steering knuckle.

  69. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  70. SEPARATE TIE ROD END SUB-ASSEMBLY LH


    1. Remove the cotter pin and nut.

    2. A01CFZ0E01

      Install SST to the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure that the upper end of the tie rod end and SST are aligned.

    3. Using SST, separate the tie rod end from the steering knuckle.

      A01CETJE01
      SST
      09960-20010   ( 09961-02010 )

      CAUTION:

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

      Note


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

      • 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.

  71. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  72. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


    1. A01CCQY

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

      Note

      If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

  73. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  74. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A01CED2

      Remove the 2 bolts and separate the front disc brake caliper assembly from the steering knuckle.

      Note

      Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose.

  75. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  76. REMOVE FRONT DISC (for LH Side)


    1. A01CEYHE01

      Put matchmarks on the front disc and front axle hub.

      Tech Tips

      The above step is not necessary when the front disc will be replaced.

    2. Remove the front disc.

  77. REMOVE FRONT DISC (for RH Side)

    Tech Tips

    Perform the same procedure as for the LH side.

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


    1. A01CDOO

      Remove the bolt and 2 nuts, and then pull down the front lower suspension arm sub-assembly to separate the front lower suspension arm sub-assembly from the front lower ball joint.

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

    Tech Tips

    Perform the same procedure as for the LH side.

  80. REMOVE FRONT AXLE ASSEMBLY LH


    1. A01CGF8

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

      Tech Tips

      If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and a hammer.

    2. A01CG6M

      Remove the 2 bolts and 2 nuts.

    3. Remove the front axle assembly from the front drive shaft assembly.

      Note


      • Do not deform the dust cover.

      • Do not damage the outboard joint boot.

      • Do not damage the speed sensor rotor.

      • Do not drop the front axle assembly.

      • Use the wire or an equivalent tool to hang the front drive shaft assembly.

  81. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  82. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01CB60E01

      Using SST, remove the front drive shaft assembly LH.

      SST
      09520-00031
      09520-01010
      09521-00020

      Note


      • Do not damage the transaxle case oil seal.

      • Do not damage the inboard joint boot.

      • Do not drop the front drive shaft assembly LH.

  83. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. A01CEXT

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

  84. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A01CEWK

      Remove the 2 bolts and front drive shaft assembly RH from the vehicle.

      Note


      • Do not damage the front transaxle case oil seal.

      • Do not damage the inboard joint boot.

      • Do not drop the front drive shaft assembly RH.

  85. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. A01CFHL

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

  86. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A01CBGH

      Remove the 2 bolts and flywheel housing under cover.

  87. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT


    1. A01CAM5E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01CCJZ

      Remove the 6 drive plate and torque converter clutch setting bolts.

      Tech Tips

      There will be one black colored bolt.

  88. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01CFMT

      Remove the 4 bolts and the front suspension member reinforcement LH.

  89. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  90. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY


    1. A01CEH2

      Remove the 3 bolts and front suspension member brace sub-assembly (LH side).

    2. Perform the same procedure for the front suspension member brace sub-assembly (RH side).

  91. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01CE3N

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

    2. A01CGH4

      Using a transmission jack or equivalent, support the front suspension crossmember sub-assembly.

    3. A01CFKS

      Remove the 2 bolts.

    4. Slowly lower the jack, and remove the front suspension crossmember sub-assembly from the vehicle.

  92. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01CDY9

      Set the engine lifter.

      Note


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

      • Do not position a height adjustment attachment or plate lift attachment onto the front crossmember sub-assembly.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • 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. A01CBRR

      Remove the 4 bolts and front crossmember sub-assembly.

    3. A01CD6U

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

    4. A01CD38

      Remove the through bolt and nut, and separate the engine mounting insulator LH.

    5. Carefully remove the engine with transaxle 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.

    6. A01CBMWE12

      Install the No. 1 and No. 2 engine hangers with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
      Part No.
      Item Part No.
      No. 1 engine hanger 12281-31120
      No. 2 engine hanger 12282-31100
      Bolt 91671-10825

    7. Attach the sling device to the engine hangers and chain block.

  93. DISCONNECT FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A01CF9HE01

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

  94. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01CCPE

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

  95. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A01CF63

      Remove the through bolt and rear engine mounting insulator.

  96. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH


    1. A01CF8D

      Disconnect the 4 clamps and remove the nut and bracket.

    2. A01CD03

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

  97. REMOVE ENGINE MOUNTING INSULATOR LH


    1. A01CDHV

      Disconnect the clamp and remove the bolt and bracket.

    2. A01CFND

      Remove the 4 bolts and engine mounting insulator LH.

  98. REMOVE MANIFOLD STAY


    1. A01CF09

      Remove the 2 bolts, nut and manifold stay.

  99. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01CFRU

      Remove the 3 bolts and front engine mounting bracket.

  100. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01CDII

      Remove the 3 bolts and rear engine mounting bracket.

  101. REMOVE V-RIBBED BELT


    1. A01CEBW

      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.

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

  102. REMOVE GENERATOR ASSEMBLY


    1. A01CDNX

      Remove the 2 bolts.

    2. A01CFT4

      Remove the terminal cap.

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

    4. Disconnect the generator connector from the generator assembly.

    5. Disconnect the connector from the compressor and magnetic clutch.

    6. Disconnect the wire harness clamp.

    7. A01CFVS

      Remove the 2 bolts.

    8. A01CG4Z

      Remove the bolt from the cylinder block.

    9. Disconnect the wire harness clamp and remove the generator assembly.

    10. A01CDVD

      Remove the bolt and bracket.

  103. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY


    1. w/ No. 2 Air Conditioning Tube:


      1. A01CATD

        Disengage each clamp.

      2. Disconnect each connector.

    2. w/o No. 2 Air Conditioning Tube:


      1. A01CGHB

        Disengage each clamp.

      2. Disconnect each connector.

    3. A01CDP0

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

  104. REMOVE STARTER ASSEMBLY


    1. A01CD0EE01

      Disconnect the starter connector.

    2. Open the terminal cap, remove the nut and disconnect the starter wire.

    3. A01CFED

      Remove the bolt and wire harness clamp bracket.

    4. A01CDFS

      Remove the 2 bolts and starter.

  105. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01CC2N

      Remove the 3 bolts and drive shaft bearing bracket.

  106. REMOVE ENGINE WIRE

  107. REMOVE TRANSMISSION BREATHER SKIRT


    1. A01CBQZE02

      Slide the clip and disconnect the breather plug hose from the transmission breather skirt.

    2. Remove the bolt and transmission breather skirt from the engine cylinder head.

  108. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY


    1. A01CBVQ

      Remove the 11 bolts and transaxle.

      Note

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

  109. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01CAM5E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01CDNY

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