ENGINE ASSEMBLY REMOVAL

Note

When the manual 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.

REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

Start up the engine.
Switch the A/C on.
Turn the blower switch to on.
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.
Stop the engine.

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

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

Connect the refrigerant recovery unit.
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.

DISCHARGE FUEL SYSTEM PRESSURE

Click here

DRAIN ENGINE COOLANT

CAUTION:

To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

Text in Illustration
*1	Water Filler Cap Sub-assembly	*2	Radiator Drain Cock Plug
*3	Air Bleed Valve	-	-

Loosen the radiator drain cock plug.

Tech Tips

Collect the coolant in a container and dispose of it according to the regulations in your area.
Remove the water filler cap sub-assembly.

DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)
1. Using a socket hexagon wrench (6 mm), remove the drain plug and gasket and drain the fluid.
2. Text in Illustration
  
  *1 No. 1 Transmission Oil Filler Tube
  
  Using a socket hexagon wrench (6 mm), remove the No. 1 transmission oil filler tube and drain the fluid.
3. Using a socket hexagon wrench (6 mm), install the No. 1 transmission oil filler tube.
  
  Torque:
  
  0.8 N*m { 8.2 kgf*cm, 7 in.*lbf }
4. Install a gasket and temporarily tighten the drain plug with a socket hexagon wrench (6 mm).
  
  Tech Tips
  
  Because the drain plug will be removed again, the gasket can be reused at this time.
DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)
Text in Illustration

*1 Filler plug

*2 Drain plug
1. Stop the vehicle in a level place.
2. Remove the manual transmission filler plug and the gasket.
3. Remove the manual transmission drain plug and gasket, and then drain the manual transaxle oil.
REMOVE FRONT WHEELS
REMOVE FRONT BUMPER COVER
1. Apply protective tape, as shown in the illustration.
  
  Text in Illustration
  
  *1 Protective tape
2. Using a screwdriver, remove the 2 pin hold clips.
  
  Tech Tips
  
  Use the same procedure for the RH and LH sides.
3. Remove the 5 clips.
4. Remove the 4 screws.
5. Disengage the 6 claws and remove the front bumper cover.
6. Disconnect the connectors.
  
  Tech Tips
  
  If the vehicle is equipped with fog lights, disconnect the connector.
REMOVE FRONT BUMPER ENERGY ABSORBER SUB-ASSEMBLY
1. Remove the 14 screws and front bumper energy absorber.
REMOVE WINDSHIELD WIPER MOTOR AND LINK
1. Remove the windshield wiper motor and link Click here.
REMOVE FRONT FLOOR COVER LH
REMOVE FRONT FLOOR COVER RH
REMOVE NO. 2 ENGINE UNDER COVER
REMOVE NO. 3 ENGINE UNDER COVER
1. Remove the 3 clips and the No. 3 engine under cover.
REMOVE NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)
1. Remove the 2 nuts and the No. 1 cooler cover.
REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)
1. Remove the 2 bolts, nut and No. 1 engine cover.
REMOVE FRONT EXHAUST PIPE ASSEMBLY
1. Disconnect the heated oxygen sensor connector.
2. Remove the 2 bolts and the 2 compression springs, and disconnect the front exhaust pipe assembly from the tail exhaust pipe assembly.
3. Remove the 2 bolts and the 2 compression springs, and remove the front exhaust pipe assembly from the exhaust manifold.
REMOVE NO. 1 V-RIBBED (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)
Text in Illustration

*1 Bolt A

*2 Adjusting Bolt B
1. Loosen the bolt A.
2. Turn adjusting bolt B to release the tension and remove the No. 1 V-ribbed belt from the pulleys.
REMOVE FAN AND GENERATOR V-RIBBED BELT
Text in Illustration

*1 4 mm Bi-hexagon Wrench

*a Turn
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.
2. While turning the V-ribbed belt tensioner counterclockwise, align the holes, and then insert a 4 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner in place.
REMOVE BATTERY
1. Disconnect the cables from the battery terminals.
2. Remove the 2 nuts and the battery clamp.
3. Remove the battery.
REMOVE BATTERY TRAY
1. Remove the battery tray.
REMOVE NO. 2 BATTERY CARRIER
1. Disengage the harness clamp from the No. 2 battery carrier.
2. Remove the 3 bolts and the No. 2 battery carrier.
REMOVE AIR CLEANER AND HOSE
1. Disconnect the wire harness clamp and the intake mass air flow meter connector.
2. Disconnect the ventilation hose.
3. Loosen the hose clamp and disconnect the air cleaner hose.
4. Text in Illustration
  
  *1 Clamp
  
  *2 Guide
  
  Disengage the 2 clamps and 2 guides and remove the air cleaner and hose.
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
DISCONNECT ENGINE WIRE
1. Turn the lever and disconnect the ECM connector.
  
  Text in Illustration
  
  *1 Lock Button B
  
  *2 Lever
  Note
  - Depress the lock button B while depressing A, and turn the lever.
  - Do not turn the lever more than 90°.
  - Do not turn the lever before depressing the lock button B.
2. Disconnect the 2 connectors from the battery terminal.
3. Remove the engine room junction block cover.
4. Remove the 4 connectors and 2 clamps from the engine room junction block
5. Remove the ground bolt and harness clamp and disconnect the engine wire.
DISCONNECT RADIATOR RESERVOIR TANK HOSE
1. Disengage the radiator reservoir tank hose from the hose clamp.
2. Loosen the clip and disconnect the radiator reservoir tank hose.
REMOVE NO. 3 RADIATOR HOSE
1. Loosen the 2 clips and remove the No. 3 radiator hose.
DISCONNECT NO. 2 RADIATOR HOSE
1. Loosen the clamp and disconnect the radiator hose from the radiator assembly.
DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
1. Loosen the clip and disconnect the No. 1 fuel vapor feed hose.
REMOVE EFI FUEL PIPE CLAMP
1. Remove the EFI fuel pipe clamp.
DISCONNECT FUEL TUBE SUB-ASSEMBLY
1. Pinch the tube connector and pull out the fuel pipe.
  Note
  
  Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
  
  The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
  
  If the connector and the pipe are stuck, push and pull on the connector to release them while pinching the retainer. Pull the connector out of the pipe carefully.
  
  Do not use any tools.
  
  Do not bend or twist the tubes.
  
  Protect the contact surface by covering it with a plastic bag.
  
  Do not damage any of the clips. If a clip is damaged, replace it.
DISCONNECT INLET HEATER WATER HOSE
1. Loosen the clip and disconnect the inlet heater water hose.
DISCONNECT OUTLET HEATER WATER HOSE
1. Loosen the clip and disconnect the outlet heater water hose.
SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)
1. Remove the nut and disconnect the transmission control cable from the transmission control shaft lever.
2. Remove the clip and separate the transmission control cable from the No. 1 transmission control cable bracket.
SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
1. Remove the 2 clips <B>.
2. Remove the 2 <A> clips and separate the 2 cables from the transaxle.
DISCONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)
1. Using a union nut wrench 10 mm, disconnect the No. 1 clutch hose from the clutch release cylinder to flexible hose tube.
DISCONNECT UNION TO CHECK VALVE HOSE
1. Loosen the clip and disconnect union to check valve hose.
REMOVE FRONT AXLE SHAFT LH NUT
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.
REMOVE FRONT AXLE SHAFT RH NUT

Tech Tips

The removal procedure for the RH side is the same as that for the LH side.
SEPARATE FRONT SPEED SENSOR LH
1. Remove the 3 bolts and separate the speed sensor and flexible hose.
2. 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.
SEPARATE FRONT SPEED SENSOR RH

Tech Tips

The removal procedure for the RH side is the same as that for the LH side.
SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
1. Remove the nut and separate the stabilizer link from the shock absorber.
SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

The removal procedure for the RH side is the same as that for the LH side.
SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH
1. Remove the clip and castle nut.
2. 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.
  
  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.
SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

Tech Tips

The removal procedure for the RH side is the same as that for the LH side.
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.
SEPARATE FRONT AXLE ASSEMBLY RH

Tech Tips

The removal procedure for the RH side is the same as that for the LH side.
REMOVE DRIVE SHAFT HEAT INSULATOR
1. Remove the 2 bolts and the 2 nuts, and the drive shaft heat insulator.
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using a screwdriver and hammer, remove the drive shaft.
  Note
  - Do not damage the oil seal.
  - Do not damage the inboard joint boot.
  - Do not drop the drive shaft.
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

Tech Tips

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

Text in Illustration
*1	No. 1 Transmission Oil Filler Tube

Text in Illustration
*1	Filler plug
*2	Drain plug

Text in Illustration
*1	Protective tape

Text in Illustration
*1	Bolt A
*2	Adjusting Bolt B

Text in Illustration
*1	4 mm Bi-hexagon Wrench
*a	Turn

Text in Illustration
*1	Clamp
*2	Guide

Text in Illustration
*1	Lock Button B
*2	Lever

Text in Illustration
*1	Place the wrench here

REMOVE FRONT FRAME ASSEMBLY

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

Text in illustration
*1	Strong Rope

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

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

Remove the 4 bolts and remove the front frame assembly.

SEPARATE DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
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.
3. Remove the bolt and the separate the discharge hose.
SEPARATE SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
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.
REMOVE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Remove the 2 bolts and the 2 nuts.
2. Using a "TORX" socket wrench (E8), remove the 2 stud bolts and the compressor.
REMOVE ENGINE MOVING CONTROL ROD COVER (for Cold Area)
1. Remove the 2 clips and the engine moving control rod cover.
REMOVE ENGINE MOVING CONTROL ROD
1. Remove the bolt and the engine moving control rod.

REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Set the engine lifter.
Note
- Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
- Securely suspend 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.
Remove the rope that secures the engine assembly and the body.
Remove the bolt, 2 nuts and disconnect the engine mounting insulator RH.
Remove the through bolt and nut and disconnect the engine mounting insulator LH.

Text in Illustration
*1	No. 1 Engine Hanger (Part No. 12281-47010)
*2	No. 2 Engine Hanger (Part No. 12282-47010)
*3	Bolt (Part No. 91552-81040)

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

Torque:: 43 N*m { 438 kgf*cm, 31 ft.*lbf }

Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

REMOVE WATER BY-PASS HOSE ASSEMBLY (for CVT)
1. Disengage the clamp and separate the breather hose from the water by-pass hose.
2. Remove the bolt and separate the water by-passe hose from the CVT.
3. Loosen the 2 clips and separate the 2 water by-pass hoses from the oil cooler.
4. Disengage the hose clamp.
5. Loosen the 2 clip and remove the water by-pass hose.
REMOVE WATER BY-PASS HOSE ASSEMBLY (for Manual Transaxle)
1. Disengage the hose clamp.
2. Loosen the clip and remove the water by-pass hose.
REMOVE INLET HEATER WATER HOSE (for Manual Transaxle)
1. Loosen the clip and remove the inlet heater water hose.
REMOVE NO. 1 RADIATOR HOSE
1. Loosen the 2 clips and remove the No. 1 radiator hose.
REMOVE WATER FILLER ASSEMBLY
1. Remove the bolt and the water filler.
REMOVE NO. 2 RADIATOR HOSE
1. Loosen the clip and remove the No. 2 radiator hose.
REMOVE ENGINE WIRE
1. Remove the 2 ground bolts and separate the ground wire from the cylinder block.
2. Remove the nut from the starter.
3. Remove the bolt and separate the engine wire from the wiring harness bracket.
4. Remove the terminal cap from the generator.
5. Remove the nut from the generator.
6. Text in Illustration
  
  *A CVT
  
  *B Manual Transaxle
  
  Remove the ground bolt and separate the ground wire from the transaxle.
7. Disconnect all of the clamps and connectors and remove the engine wire from the engine assembly with transaxle.
REMOVE DRIVE SHAFT HEAT INSULATOR BRACKET
1. Remove the 2 bolts and remove the drive shaft heat insulator bracket from the engine.
REMOVE FLYWHEEL HOUSING SIDE COVER
1. Disengage the claw by pulling it outward and remove the flywheel housing side cover.
REMOVE STARTER ASSEMBLY
1. Open the terminal cap.
2. Remove the nut and disconnect terminal 30.
3. Disconnect the connector.
4. Remove the 2 bolts and the starter assembly.
REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)
1. Use SST to hold the crankshaft pulley in place.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
2. Remove the 6 drive plate and torque converter setting bolts.
REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)
1. Remove the 9 bolts and the CVT.
  
  Note
  
  Do not twist the CVT when removing it from the engine, because the knock pins could be damaged.
REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)
1. Using SST, hold the crankshaft.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
2. Remove the 8 bolts, the rear drive plate spacer, the drive plate and the front drive plate spacer.
REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
1. Remove the 10 bolts and the manual transaxle.
REMOVE BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)
1. Using a union nut wrench 10 mm, separate the bleeder clutch release tube.
2. Remove the bolt and bleeder clutch release tube.
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
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.
REMOVE CLUTCH TUBE BOOT (for Manual Transaxle)
REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
1. Remove the 3 bolts and the clutch release with bearing cylinder assembly together with the bleeder clutch release tube.
REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)
1. Using a union nut wrench 10 mm, separate the clutch release tube from the clutch release with bearing cylinder assembly.
REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
1. Text in Illustration
  
  *a Matchmark
  
  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.
REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)
REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
1. Using SST, hold the crankshaft.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
2. Remove the 8 bolts, the rear flywheel plate spacer, the flywheel and the front flywheel plate spacer.

Text in Illustration
*A	CVT
*B	Manual Transaxle

Text in Illustration
*a	Matchmark

REMOVE INNER OIL SEAL (for Manual Transaxle)

Text in Illustration
*1	Protective Tape
*a	Cut Position
*b	Pry Out

Using a knife, cut off the lip of the inner oil seal.

Using a screwdriver with its tip wrapped with protective tape, pry out the inner oil seal.

Note

Be careful not to damage the one-way clutch assembly.

REMOVE ONE-WAY CLUTCH ASSEMBLY (for Manual Transaxle)
1. Turn the one-way clutch assembly counterclockwise while removing it.
INSPECT RING GEAR SUB-ASSEMBLY (for Manual Transaxle)
1. Visually check the one-way clutch assembly installation surface for damage, deformation, and cracks.
2. Check that the snap ring is not broken and fits correctly into the crankshaft bearing groove.
REMOVE RING GEAR SUB-ASSEMBLY (for Manual Transaxle)
1. Using a screwdriver, remove the snap ring.
2. Remove the ring gear sub-assembly from the crankshaft.
  
  Note
  
  Do not forcefully pry the ring gear during removal.
INSPECT ONE-WAY CLUTCH ASSEMBLY (for Manual Transaxle)
1. Text in Illustration
  
  *a Lock
  
  *b Free
  
  Make sure that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
  
  If the one-way clutch assembly does not operate normally, replace it.
INSTALL ENGINE STAND
1. Using a sling device and chain block, install the engine assembly to the engine stand.
  Note
  - Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.
  - Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tech Tips

Only perform this procedure when replacement of the engine moving mounting insulator RH is necessary.
1. Remove the 3 bolts and the transverse engine engine mounting insulator.
REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Tech Tips

Only perform this procedure when replacement of the transverse engine engine mounting insulator is necessary.
1. Remove the 5 bolts and the transverse engine engine mounting insulator.

Text in Illustration
*a	Lock
*b	Free