ENGINE ASSEMBLY REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  2. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY


    1. Remove the front wiper motor and link Click here.

  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  4. SECURE STEERING WHEEL


    1. A010KCN

      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.

  5. REMOVE ENGINE ROOM SIDE COVER


    1. A00DSOB

      Remove the clip and engine room side cover.

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


    1. Loosen the nut and disconnect the cable.

      Note

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

  7. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL


    1. Loosen the nut and disconnect the cable.

  8. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A00DQR1

      Remove the 8 clips and radiator support opening cover.

  9. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

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

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp from the battery carrier, and then remove the battery clamp.

  11. REMOVE BATTERY

  12. REMOVE BATTERY TRAY

  13. REMOVE BATTERY CARRIER


    1. A005RI3

      Disconnect the 2 wire harness protector clamps.

    2. Remove the 4 bolts and battery carrier.

  14. REMOVE FRONT WHEELS

  15. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A005U7U

      Remove the 4 screws and 2 bolts.

      Tech Tips

      Pull down the fender liner so that the front lower bumper absorber can be removed in the next step.

    2. A005TN1

      Remove the 3 screws, 8 bolts and front lower bumper absorber.

  16. REMOVE NO. 1 ENGINE UNDER COVER


    1. A005VAK

      Remove the 5 clips and under cover.

  17. REMOVE NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)


    1. A005U17

      Remove the 3 bolts and under cover.

  18. REMOVE CENTER NO. 4 ENGINE UNDER COVER


    1. A00DU94

      Remove the 5 clips and under cover.

  19. REMOVE REAR ENGINE UNDER COVER RH


    1. A005V2G

      Remove the 5 clips and under cover.

  20. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A005RNJ

      Remove the 2 nuts and engine cover.

  21. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

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

    3. Clean and install the oil pan drain plug with a new gasket.

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

  22. DRAIN ENGINE COOLANT

    Tech Tips

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

    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.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap. Then drain the coolant from the radiator.

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      A005R92E01
      Text in Illustration
      *1 Radiator Reservoir Cap *3 Cylinder Block Drain Cock Plug
      *2 Radiator Reservoir *4 Radiator Drain Cock Plug

    4. Tighten the radiator drain cock plug by hand.

    5. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  23. DISCONNECT RADIATOR RESERVOIR


    1. A00DPOD

      Remove the 2 bolts and disconnect the radiator reservoir.

  24. REMOVE AIR CLEANER CAP AND HOSE


    1. A005VS4

      Disconnect the mass air flow meter connector and wire harness.

    2. Disconnect the purge VSV.

    3. A005VYI

      Disconnect the No. 2 ventilation hose from the cylinder head cover.

    4. Disconnect the No. 2 fuel vapor feed hose from the air cleaner hose.

    5. Squeeze the tabs of the No. 1 air cleaner hose clamp, and then disconnect the No. 1 air cleaner hose from the throttle body.

    6. A005R8E

      Unfasten the 3 hook clamps, and then remove the air cleaner cap and hose.

  25. REMOVE AIR CLEANER CASE


    1. A005S4X

      Disconnect the engine wire.

    2. Remove the 3 bolts and air cleaner case.

  26. REMOVE NO. 1 RADIATOR HOSE


    1. A005VNT

      Disconnect the No. 1 radiator hose clamp.

    2. Disconnect the No. 1 radiator hose from the No. 2 water by-pass hose.

    3. Remove the No. 1 radiator hose.

  27. REMOVE NO. 2 RADIATOR HOSE


    1. A005SZ4

      Remove the No. 2 radiator hose.

  28. DISCONNECT OIL COOLER HOSE


    1. A005VY6

      Disconnect the 2 oil cooler hoses.

  29. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A00DSK0

      Remove the 9 bolts and outer cowl top panel.

  30. DISCONNECT CONNECTOR TUBE HOSE


    1. A00DQ41

      for LHD:

      Disconnect the connector tube hose.

    2. A00DSXK

      for RHD:

      Disconnect the connector tube hose.

  31. DISCONNECT HEATER WATER HOSE


    1. A00DT2K

      Disconnect the breather hose.

    2. Disconnect the 2 heater water hoses.

  32. DISCONNECT FUEL TUBE

    A00DPJXE02

    Note

    Do not forcibly bend or twist the fuel main tube.


    1. Remove the fuel tube from the fuel hose clamp.

    2. Remove the fuel pipe clamp.

    3. Wipe off any dirt on the fuel tube connector.

    4. Hold the fuel tube connector and install SST.

      SST
      09268-21010

    5. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.

    6. Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST.

    7. Mount the retainer of the fuel tube connector onto the chamfered part of SST.

    8. A00DUB5E14

      Slide SST and the fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.

    9. Drain the fuel remaining inside the fuel tube.

    10. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected parts.

      Text in Illustration
      *1 O-Ring
      *2 Retainer
      *3 Nylon Tube
      *4 Housing
      *5 Pipe

  33. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A00DUH1

      Remove the nut and disconnect the control cable from the control shaft lever.

    2. Remove the clip and disconnect the control cable from the control cable bracket.

    3. Disconnect the control cable from the control cable bracket.

    4. A00DSA8

      Remove the bolt and disconnect the control cable.

  34. REMOVE FAN & GENERATOR V BELT


    1. A005USYE01

      Using SST, slowly turn the V-ribbed belt tensioner clockwise.

      SST
      09216-42010

      CAUTION:

      Be careful not to pinch your fingers between the parts.

      Note


      • Make sure that SST and other tools are set to the tensioner securely.

      • When compressing the V-ribbed belt tension, slowly turn the tensioner.

    2. Remove the belt from each pulley and slowly return the tensioner.

      CAUTION:

      Be careful not to pinch your fingers between the parts.

  35. REMOVE GENERATOR ASSEMBLY


    1. A005UTC

      Disconnect the generator connector.

    2. Open the terminal cap.

    3. Remove the nut and disconnect the generator wire.

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

    5. Disconnect the wire harness clamp.

    6. A005TXQ

      Remove the 2 bolts and generator.

  36. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A005SD0

      Remove the bolt and disconnect the discharge hose sub-assembly from the compressor assembly with pulley.

      Note

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

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

      Note

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

  37. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A005RKU

      Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.

      Note

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

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

      Note

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

  38. DISCONNECT ENGINE WIRE


    1. A00DQ7I

      Disconnect the 3 connectors from the engine room relay block.

    2. Remove the 2 nuts and disconnect the wire harnesses from the engine room relay block.

    3. Using a screwdriver, unlock the 2 claws.

    4. Pull the engine wire upward.

    5. Disconnect the clamp and ECM connector Click here.

    6. A00DRU3

      Remove the bolt and disconnect the ground cable and clamp.

    7. A00DTSB

      Remove the bolt and disconnect the ground cable and 2 clamps.

  39. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the front exhaust pipe Click here.

  40. REMOVE FRONT DRIVE SHAFT ASSEMBLY


    1. Remove the front drive shaft Click here.

  41. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A00OJTQ

      Fold back the floor carpet, and then remove the 2 clips and then column hole cover silencer sheet.

  42. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A00OMQT

      Remove the bolt.

      Note

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

    2. A00ONO5E01
      Text in Illustration
      *1 Matchmark

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

    3. Disconnect the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.

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

    A010G5CE02

    1. Remove clip A and the No. 1 steering column hole cover and detach clip B from the body.

      Note

      Do not damage clip A or B.

      Text in Illustration
      *1 Lip
      *2 Clip B
      *3 Clip A
      *4 Lip

  44. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT


    1. A00DUW9

      Remove the 8 bolts and 2 front suspension member reinforcements.

  45. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A00DRMH

      Remove the 6 bolts and front crossmember.

  46. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A00DU44

      Remove the through bolt, nut and engine mounting insulator.

  47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A00DUB4

      Set the engine assembly with transaxle on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. A00DRK9

      Disconnect the air conditioning tube.

    3. Remove the bolt and cooler bracket.

    4. A00DUCC

      Disconnect the 2 air conditioning tubes.

    5. Remove the bolt, nut and cooler bracket.

    6. A00DQKG

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

    7. A00DSJM

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

    8. A00DQZD

      Remove the 6 bolts and 2 front suspension member brace rears.

    9. A00DTWP

      Remove the 2 bolts and front suspension crossmember.

    10. Operate the engine lifter and slowly remove the engine 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.

    11. A00DPOIE02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 and No. 2 engine hangers with bolts as shown in the illustration.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

      Tech Tips

      Item Part No.
      No. 1 engine hanger 12281-28010, 12281-0H010
      No. 2 engine hanger 12282-28010, 12282-0H010
      Bolt 91552-81020
    12. A00DR18

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

  48. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A00DQ00E01

      Remove the 3 bolts and bracket.

  49. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

    A005RXD

    1. Detach the 2 clamps.

    2. Disconnect the connector.

    3. A005UQF

      Remove the 2 bolts and 2 nuts.

    4. A005VR3

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

  50. REMOVE STARTER ASSEMBLY


    1. A005RRH

      Disconnect the starter connector.

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

    3. A005VY7

      Remove the 2 bolts and starter.

  51. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY


    1. Remove the automatic transaxle Click here.

  52. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A00DPUYE03

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00DTZKE04

      Remove the 8 bolts, rear drive plate spacer, drive plate and front drive plate spacer.

  53. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  54. INSTALL ENGINE ON ENGINE STAND


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

    2. Remove the 2 bolts and No. 1 and No. 2 engine hangers.

  55. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A00DRW8

      Remove the bolt and front suspension crossmember from the engine.

  56. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

    A00DQ5E

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


    1. Remove the 2 nuts, 2 bolts and engine mounting insulator.

  57. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

    A00DSP6

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


    1. Remove the 4 bolts and engine mounting insulator.

  58. REMOVE ENGINE MOUNTING INSULATOR RH

    Tech Tips

    A00DU8H

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


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