ENGINE ASSEMBLY REMOVAL

Note


  • When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

  • After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester Click here.


  1. REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


    1. Start up the engine.

    2. Switch the A/C on.

    3. Turn the blower switch to on.

    4. Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the remaining compressor oil from each component, in the cooler compressor.

    5. Stop the engine.

    6. Remove the caps from the service valves on the refrigerant line.

      A011ADWE02
      Text in illustration
      *a Engine room side
      *b Wheel house side
      Access to Hi Pressure Side
      Engine Type RHD LHD
      1KR-FE Engine room Engine room
      1NR-FE Engine room Engine room
      1ND-TV Engine room Engine room
      Access to Low Pressure Side
      Engine Type RHD LHD
      1KR-FE Wheel house Wheel house
      1NR-FE Wheel house Wheel house
      1ND-TV Wheel house Wheel house

    7. Connect the refrigerant recovery unit.

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

      Tech Tips

      Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

  2. REMOVE FRONT WHEELS

  3. DRAIN ENGINE OIL

  4. DRAIN MANUAL TRANSAXLE OIL


    1. Drain manual transaxle oil Click here.

  5. REMOVE ENGINE UNDER COVER

    A011A8B

    1. Remove the 4 bolts, 4 clips and the engine under cover.

  6. REMOVE NO. 3 ENGINE UNDER COVER

    A01181U

    1. Remove the 3 clips and the No. 3 engine under cover.

  7. REMOVE FRONT FLOOR COVER LH

  8. REMOVE FRONT FLOOR COVER RH

  9. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly Click here.

  10. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    A011AR6

    1. Remove the 2 bolts.

    2. Disconnect the air bleed valve.

    3. Disconnect the No. 5 water by-pass hose and remove the radiator reserve tank.

  11. DISCONNECT NO. 2 AIR HOSE


    1. A011993

      Loosen the hose clamp and disconnect the No. 2 air hose.

  12. DISCONNECT NO. 3 AIR HOSE


    1. A0118R4

      Loosen the hose clamp and disconnect the No. 3 air hose.

  13. REMOVE INTERCOOLER ASSEMBLY

    A0117IZ

    1. Disengage the 2 wire harness clamps and separate the wire harness.

    2. A011BJD

      Disconnect the vacuum transmitting hose.

    3. Disconnect the intake air temperature sensor connector.

    4. A0118Q1

      Disengage the 2 wire harness clamps.

    5. A0117KV

      Remove the intercooler with the intercooler air duct.

  14. REMOVE COWL PANEL SUB-ASSEMBLY


    1. Remove the cowl panel sub-assembly Click here.

  15. REMOVE ENGINE COVER ASSEMBLY


    1. A011ACJ

      Disengage the 3 claws and remove the engine cover.

  16. REMOVE AIR CLEANER HOSE ASSEMBLY

    A011AWO

    1. Remove the air cleaner hose.

  17. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A011ADE

      Remove the 2 nuts and the battery clamp.

  18. REMOVE BATTERY

  19. REMOVE BATTERY TRAY

  20. REMOVE NO. 2 BATTERY CARRIER

    A011AR2

    1. Disconnect the 2 wire harness clamps.

    2. Remove the 3 bolts and the No. 2 battery carrier.

  21. REMOVE FUEL FILTER ASSEMBLY


    1. A011B6X

      Disconnect the 2 wire harness clamps.

    2. Disconnect the connector.

    3. A011A0C

      Disconnect the 2 connectors.

    4. A0119HL

      Disconnect the 2 fuel hose clamps from the fuel filter.

    5. Disconnect the 2 fuel hoses.

    6. A011BBN

      Loosen the fuel filter drain plug to drain fuel.

    7. Tighten the fuel filter drain plug.

    8. A0118XZ

      Remove the 2 nuts and fuel filter.

  22. REMOVE INJECTION PUMP TO FUEL FILTER FUEL HOSE

    A011ADO

    1. Disengage the hose clamp and remove the injection pump to fuel filter fuel hose.

  23. DISCONNECT NO. 2 FUEL HOSE

    A0119OP

    1. Disconnect the No. 2 fuel hose.

  24. DISCONNECT ENGINE WIRE

    A011B5U

    1. Disconnect the 3 connectors from the battery terminal.

    2. Remove the engine ground bolt.

    3. Disconnect the engine wire from the engine room junction block.


      1. Remove the junction block cover.

      2. A011B5B

        Disconnect the 4 engine wire connectors and clamp.

  25. REMOVE NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)

    A0119EA

    1. Remove the 2 nuts and the No. 1 cooler cover.

  26. REMOVE NO. 4 ENGINE COVER (w/ No. 4 Engine Cover)

    A0117VM

    1. Remove the 2 bolts, nut and the No. 4 engine cover.

  27. REMOVE NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)

    A0119GZE01

    1. Loosen bolts A and B.

    2. Remove the No. 1 V belt.

  28. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)

    A011881

    1. Remove the 3 bolts and the No. 2 idle pulley.

  29. REMOVE FAN AND GENERATOR V BELT

    A011A8N

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

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

  30. DISCONNECT UNION TO CONNECTOR TUBE HOSE

    A01178S

    1. Disconnect the union to connector tube hose.

  31. DISCONNECT INLET HEATER WATER HOSE

    A01178F

    1. Disconnect the inlet heater water hose.

  32. DISCONNECT OUTLET HEATER WATER HOSE

    A011BWD

    1. Disconnect the outlet heater water hose.

  33. REMOVE NO. 1 RADIATOR HOSE

    A0119JP

    1. Remove the No. 1 radiator hose.

  34. REMOVE NO. 2 AIR HOSE

    A0117IW

    1. Remove the No. 2 air hose.

  35. REMOVE NO. 1 AIR TUBE

    A011AKQ

    1. Remove the nut and the No. 1 air tube.

  36. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    A011B2OE01

    1. Remove the 2 clips*1 and disconnect the 2 cables from the transaxle.

    2. Remove the 2 clips*2 and disconnect the 2 cables from the control cable bracket.

  37. DISCONNECT CLUTCH HOSE

    A011BHN

    1. Using a union nut wrench 10 mm, disconnect the clutch hose from the clutch release cylinder to flexible hose tube.

    2. Remove the clip.

  38. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. Remove the tail exhaust pipe assembly Click here.

  39. REMOVE FRONT AXLE HUB NUT LH

    A0119FQE01

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

      • Do not damage the threads of the drive shaft.

    2. Using a 30 mm socket wrench, remove the axle hub nut.

  40. REMOVE FRONT AXLE HUB NUT RH

    Tech Tips

    Perform the same procedure as above on the opposite side.

  41. SEPARATE FRONT SPEED SENSOR

    A011BBV

    1. Remove the 3 bolts and separate the speed sensor and flexible hose.

    2. A0118LW

      Remove the bolt and separate the speed sensor from the steering knuckle.

      Note


      • Keep the speed sensor tip and installation area free of foreign matter.

      • Remove the speed sensor without turning it from its original installation angle.

  42. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    A011A43

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

  43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as above on the opposite side.

  44. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    A011ABK

    1. Remove the cotter pin and castle nut.

    2. A0117XGE01

      Install SST (spacer B) to the threaded section of the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

    3. Using SST, separate the tie rod end from the front axle assembly.

      A0119EDE01
      Text in Illustration
      *1 Place the wrench here
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

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

      • Do not damage the ball joint dust cover.

      • Do not damage the front disc brake dust cover.

  45. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as above on the opposite side.

  46. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH

    A01175R

    1. Remove the clip and castle nut.

    2. A01170FE01

      Install SST (spacer B) to the threaded section of the lower ball joint.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure the upper ends of the threaded section of the lower ball joint and SST (spacer B) are aligned.

    3. Using SST, separate the front lower suspension arm from the front axle assembly.

      A0118S3E01
      Text in Illustration
      *1 Place the wrench here
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

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

      • Do not damage the lower ball joint dust cover.

      • Do not damage the drive shaft outboard joint boots.

      • Do not damage the front disc brake dust cover.

  47. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as above on the opposite side.

  48. SEPARATE FRONT AXLE ASSEMBLY LH


    1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting between the drive shaft and front axle.

      Tech Tips

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

    2. Push the front axle out of the vehicle to remove the drive shaft from the front axle.

      Note


      • Do not push the front axle further out of the vehicle than is necessary.

      • Do not damage the outboard joint boot.

      • Do not damage the speed sensor rotor.

      • Suspend the drive shaft with a piece of string or the equivalent.

  49. SEPARATE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as above on the opposite side.

  50. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    A0117PSE01

    1. Using SST, remove the drive shaft.

      SST
      09520-01010
      09520-24010   ( 09520-32040 )

      Note


      • Do not damage the oil seal.

      • Do not damage the inboard joint boot.

      • Do not drop the drive shaft.

  51. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side as for the LH side.

  52. REMOVE FRONT FRAME ASSEMBLY

    A011B7CE01

    1. Pass a strong rope through hole (A) in the engine mounting control bracket and tie it securely to the body.

      Text in illustration
      *1 Strong Rope

      CAUTION:

      When the engine moving control rod is separated, the engine assembly moves towards the front of the vehicle and will contact components near the engine if not fastened tightly.

    2. Remove the bolt and separate the engine moving control rod from engine mounting control bracket.

    3. A0118HR

      Remove the 2 bolts.

    4. A0117CAE01
      Text in illustration
      *1 RH Side
      *2 LH Side
      *3 Wooden Block

      Support the front frame assembly with 4 wooden blocks and the jack.

    5. Remove the 4 bolts and remove the front frame assembly.

  53. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    A0116XX

    1. Remove the bolt and disconnect the discharge hose from the compressor.

    2. Remove the O-ring from the discharge hose.

      Note

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

  54. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    A0119BD

    1. Remove the bolt and disconnect the suction hose from the compressor.

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

      Note

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

  55. REMOVE ENGINE MOVING CONTROL ROD COVER (for Cold Area)

    A0117UX

    Tech Tips

    Only perform this procedure when replacement of the engine moving control rod is necessary.


    1. Disengage the 2 clips and remove the engine moving control rod cover.

  56. REMOVE ENGINE MOVING CONTROL ROD

    A01190N

    Tech Tips

    Only perform this procedure when replacement of the engine moving control rod is necessary.


    1. Remove the bolt and engine moving control rod.

  57. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A011BQ8

      Set the engine lifter.

    2. A01188A

      Remove the 5 bolts, 2 nuts and disconnect the engine mounting insulator RH.

    3. A01178B

      Remove the through bolt and nut and disconnect the engine mounting insulator LH.

    4. Remove the engine assembly with transaxle.

    5. A011807E01
      Text in Illustration
      *1

      No. 1 Engine Hanger

      (Part No. 12281-33050)
      *2

      Bolt

      (Part No. 91552-81050)
      *3

      No. 2 Engine Hanger

      (Part No. 12282-33020)
      *4

      Bolt

      (Part No. 91552-81025)

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

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

      Note

      Be sure to use new bolts to install the engine hanger.

    6. Using a chain block and engine sling device, hold engine with transaxle.

  58. REMOVE ENGINE MOUNTING INSULATOR RH

    A0119ZR

    1. Remove the engine mounting insulator RH.

  59. REMOVE ENGINE MOUNTING INSULATOR LH

    A0119MZ

    Tech Tips

    Only perform this procedure when replacement of the engine moving mounting insulator LH is necessary.


    1. Remove the 5 bolts and engine mounting insulator LH.

  60. REMOVE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

    A0117ZJ

    1. Remove the 2 bolts and the 2 nuts.

    2. A011BEX

      Using a "TORX" socket wrench (E8), remove the 2 stud bolts and the compressor.

  61. REMOVE NO. 1 AIR HOSE

    A011BQL

    1. Remove the No. 1 air hose.

  62. REMOVE NO. 5 WATER BY-PASS HOSE

    A01171V

    1. Remove the No. 5 water by-pass hose.

  63. REMOVE NO. 2 RADIATOR HOSE

    A0119O8

    1. Remove the No. 2 radiator hose.

  64. REMOVE NO. 3 AIR HOSE

    A01198N

    1. Remove the No. 3 air hose.

  65. REMOVE STARTER ASSEMBLY


    1. A0119RU

      Open the terminal cap.

    2. Remove the nut and disconnect the terminal 30.

    3. Disconnect the connector.

    4. A011A6B

      Remove the 2 bolts and the starter assembly.

  66. REMOVE ENGINE WIRE

    A01182RE01

    1. Disconnect the 2 ground bolts.

    2. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.

  67. REMOVE NO. 2 TURBO INSULATOR

    A0119DJ

    1. Remove the bolt, nut and the No. 2 turbo insulator.

  68. REMOVE NO. 2 MANIFOLD SUPPORT BRACKET

    A0118VN

    1. Remove the bolt, nut and the No. 2 manifold support bracket.

  69. REMOVE MANIFOLD SUPPORT BRACKET

    A0118T4

    1. Remove the 2 bolts, nut and the manifold support bracket.

  70. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    A01170I

    1. Remove the 3 nuts and the exhaust manifold converter.

    2. Remove the gasket from the turbocharger.

  71. REMOVE CRANKSHAFT POSITION SENSOR

    A0119W3

    1. Remove the bolt, nut and the No. 1 cylinder block insulator.

    2. Remove the crankshaft position sensor.

  72. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. A0118Y9

      Remove the 8 bolts and the manual transaxle.

  73. REMOVE BLEEDER TO ACCUMULATOR TUBE


    1. A01188D

      Using a union nut wrench 10 mm, remove the bleeder to accumulator tube.

  74. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    A0119X3

    1. Using a union nut wrench 10 mm, separate the clutch release bleeder from the bleeder clutch release tube.

    2. Remove the 2 bolts and clutch release bleeder.

  75. REMOVE CLUTCH TUBE BOOT


    1. Remove the clutch tube boot from the transaxle.

  76. REMOVE BLEEDER CLUTCH RELEASE TUBE

    A011BBX

    1. Using a union nut wrench 10 mm, remove the clutch release tube from the clutch release with bearing cylinder assembly.

  77. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    A0119WU

    1. Remove the 3 bolts and the clutch release with bearing cylinder assembly together with the bleeder clutch release tube.

  78. REMOVE CLUTCH COVER ASSEMBLY

    A0118L5E01
    Text in Illustration
    *1 Matchmark

    1. Put the matchmarks on the clutch cover and the flywheel.

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

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

      Note

      Do not drop the clutch disc.

  79. REMOVE CLUTCH DISC ASSEMBLY

  80. REMOVE FLYWHEEL SUB-ASSEMBLY

    A011BE6E01

    1. Hold the crankshaft with SST.

      SST
      09213-58014
      09330-00021
    2. A011A6O

      Remove the 6 bolts and flywheel sub-assembly.

  81. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A0117J4

    1. Remove the No. 1 crankshaft position sensor plate.