ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

Some of these service operations affect the multi-mode manual transaxle system. Read the precautionary notices concerning the multi-mode manual transaxle system before servicing Click here.

Note


  • As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

  • 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 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.

PROCEDURE


  1. REMOVE REGARDING PARTS REMOVAL (for Multi-Mode Manual Transaxle)


    1. Before removing the clutch actuator or transaxle assembly from the vehicle, perform the Active Test to set the clutch actuator to the "Clamp" position Click here.

      Note

      If the actuator is not set to the "Clamp" position, the clutch fluid may be sprayed out.

      Tech Tips

      If the clutch actuator cannot be set to the "Clamp" position due to a malfunction (sticking, etc.), then the clutch fluid pressure should be released from the bleeder plug to prevent the fluid from spraying.

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

    Click here

  3. PRECAUTION

    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.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  5. REMOVE FRONT WHEELS

  6. DRAIN ENGINE COOLANT

    Click here

  7. REMOVE CENTER ENGINE UNDER COVER


    1. A005GMJ

      Remove the bolt, 9 screws, 5 clips and the center engine under cover.

  8. REMOVE ENGINE UNDER COVER RH


    1. A005HXY

      Remove the 2 bolts and the engine under cover RH.

  9. REMOVE ENGINE UNDER COVER LH

    Tech Tips

    Use the same procedures for the LH and RH side.

  10. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  11. DRAIN MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)

    Click here

  12. REMOVE FRONT WIPER MOTOR AND LINK

    Click here

  13. REMOVE FRONT NO. 1 VENTILATOR SEAL

    A005I7Z

    1. Disengage the clamp and remove the front No. 1 ventilator seal.

  14. REMOVE FRONT AIR SHUTTER SEAL RH

    Tech Tips

    Use the same procedures for the front No. 1 ventilator seal.

  15. REMOVE INNER COWL TOP REINFORCEMENT

    Click here

  16. REMOVE COWL TOP INSIDE CORNER PANEL LH

    Click here

  17. REMOVE INNER COWL TOP TO COWL BRACE


    1. A005IPU

      Remove the 2 bolts and the inner cowl top to cowl brace.

  18. REMOVE OUTER COWL TOP PANEL


    1. A005JPO

      Remove the 6 bolts and the outer cowl top panel.

  19. REMOVE NO. 1 ENGINE COVER

    A005MHJE02
    Text in Illustration
    *1 Pin
    *2 Hook
    *3 Bracket

    1. Raise the front of the No. 1 engine cover to detach the 2 pins. Then remove the 2 No. 1 engine cover hooks from the bracket, and remove the No. 1 engine cover.

  20. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    A005HUI

    1. Disconnect the No. 4 water by-pass hose.

    2. Disengage the hose clamp and disconnect the No. 5 water by-pass hose.

    3. Remove the bolt and the radiator reserve tank.

  21. REMOVE RADIATOR RESERVE TANK BRACKET

    A005KC5

    1. Remove the bolt and radiator reserve tank bracket.

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    Click here

  23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY WITH INLET AIR CLEANER

    A005GOK

    1. Remove the 3 bolts and the air cleaner case with inlet air cleaner.

  25. REMOVE AIR CLEANER BRACKET

    A005L0E

    1. Disconnect the harness clamp.

    2. Remove the 3 bolts and the air cleaner bracket.

  26. REMOVE BATTERY

    A005GQ7E01

    1. Remove the nut A.

    2. Remove the nut B and disconnect the cable from the positive (+) battery terminal.

    3. Loosen the 2 nuts and remove the battery clamp sub-assembly.

    4. Remove the battery.

  27. REMOVE BATTERY TRAY


    1. Remove the battery tray.

  28. REMOVE BATTERY CARRIER

    A005J2W

    1. Disengage the 3 clamps and disconnect the wire harness from the battery carrier.

    2. A005JG3

      Remove the 5 bolts and the battery carrier.

  29. REMOVE FAN AND GENERATOR V BELT

    Click here

  30. DISCONNECT SUCTION HOSE (w/ Air Conditioning System)

    Click here

  31. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

    Click here

  32. DISCONNECT UNION TO CONNECTOR TUBE HOSE

    A005KU8

    1. Disconnect the union to connector tube hose.

  33. DISCONNECT NO. 1 FUEL HOSE

    A005H2J

    1. Disconnect the No. 1 fuel hose.

  34. DISCONNECT NO. 2 FUEL HOSE

    A005ICH

    1. Disconnect the No. 2 fuel hose.

  35. DISCONNECT OUTLET HEATER WATER HOSE

    A005JOA

    1. Disconnect the outlet heater water hose.

  36. DISCONNECT INLET HEATER WATER HOSE

    A005MB8

    1. Disconnect the inlet heater water hose.

  37. REMOVE NO. 1 RADIATOR HOSE


    1. A005HN8

      Remove the No. 1 radiator hose.

  38. DISCONNECT NO. 2 RADIATOR HOSE

    A005LW4

    1. Disconnect the No. 2 radiator hose.

  39. REMOVE NO. 3 AIR HOSE

    A005KKS

    1. Loosen the hose clamp and remove the No. 3 air hose.

  40. REMOVE AIR PIPE SUB-ASSEMBLY

    A005JQP

    1. Loosen the 2 hose clamps and disengage the 2 wire harness clamps.

    2. Remove the bolt, 2 nuts and the air pipe sub-assembly.

  41. REMOVE NO. 2 AIR HOSE

    A005I6M

    1. Loosen the hose clamp and remove the No. 2 air hose.

  42. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    Click here

  43. DISCONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

    A005HVB

    1. Disconnect the hose clamp and the vacuum transmitting hose.

  44. SEPARATE CLUTCH HOSE

    Click here

  45. REMOVE ENGINE WIRE

    A005L82

    1. Disconnect the 3 connectors from the battery terminal.

    2. A005JPL

      Disconnect the current sensor connector and glow relay connector.

    3. A005IVJ

      Remove the engine earth bolt.

    4. A005IAS

      Disconnect the ECM connector and wire harness clamp.

    5. Remove the engine junction block cover.

    6. A005GGQ

      Disconnect the 2 connectors and the clamp from the engine room junction block.

    7. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.

  46. DISCONNECT TRANSAXLE WIRE (for Multi-Mode Manual Transaxle)


    1. A005KOD

      Disconnect the 5 connectors and 3 clamps.

  47. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  48. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  49. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  50. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  51. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  53. REMOVE OIL PAN COVER

    Click here

  54. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A005K1O

      Place wooden blocks or plate lift attachments in the positions as shown in the illustration and set an engine lifter underneath the crossmember.

      Text in Illustration
      A005HNR Attachment Placement Positions

      Note


      • Place the wooden blocks or plate lift attachments so that the front suspension crossmember sub-assembly is level.

      • As the engine assembly with transaxle is very heavy, be sure to support it securely.

    2. A005LHX

      Remove the 2 bolts and the engine mounting stay.

    3. A005LT7

      Remove the bolt and 3 nuts and separate the engine mounting insulator RH.

    4. A005KLP

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

    5. A005HYWE02
      Text in Illustration
      *a Front Side

      Remove the 6 bolts, the engine assembly with transaxle and the front suspension crossmember from the vehicle.

  55. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. A005GFW

      Remove the bolt and separate the relay block.

    2. A005HJ3

      Remove the 3 bolts and the engine mounting insulator RH.

  56. REMOVE ENGINE MOUNTING INSULATOR LH

    A005I9Z

    Tech Tips

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


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

  57. INSTALL ENGINE HANGER


    1. A005HK0E06
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 Bolt
      *3 Tab
      *a Engine rear

      Install the No. 1 engine hanger with a new bolt as shown in the illustration.

      Tech Tips

      Part Name Part No.
      No. 1 Engine Hanger 12281-33050
      Bolt 91552-81050
      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • Be sure to install the engine hanger with the tab contacting the rear side of the hole.

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

    2. A005LZSE02
      Text in Illustration
      *A 3-Bolt Type
      *B 2-Bolt Type
      *1 No. 2 Engine Hanger
      *2 Bolt

      Install the No. 2 engine hanger with a new bolt as shown in the illustration.

      Tech Tips

      Part Name Part No.

      No. 2 Engine Hanger

      (3-Bolt Type)

      		 12282-33050

      No. 2 Engine Hanger

      (2-Bolt Type)

      		 12282-33020

      Bolt

      (3-Bolt Type)

      		 91672-81025

      Bolt

      (2-Bolt Type)

      		 91552-81025
      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }
      (3-Bolt Type)
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      (2-Bolt Type)

      Note

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

  58. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


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

    2. A005K1A

      Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.

  59. REMOVE NO. 6 WATER BY-PASS HOSE

    A005KR5

    1. Remove the No. 6 water by-pass hose.

  60. REMOVE NO. 2 RADIATOR HOSE

    A005LL4

    1. Remove the No. 2 radiator hose.

  61. REMOVE NO. 2 AIR TUBE

    A005LZE

    1. Disconnect the No. 1 oil hose.

    2. Loosen the hose clamp.

    3. Remove the 2 bolts and No. 2 air tube.

  62. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  63. REMOVE STARTER ASSEMBLY (for 1.6 kW Type)

    Click here

  64. REMOVE STARTER ASSEMBLY (for 2.0 kW Type)

    Click here

  65. REMOVE NO. 2 VACUUM PIPE

    Click here

  66. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  67. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET

    Click here

  68. REMOVE NO. 3 MANIFOLD SUPPORT BRACKET

    Click here

  69. REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  70. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  71. REMOVE CLUTCH ACTUATOR ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  72. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  73. REMOVE BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)

    Click here

  74. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click here

  75. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  76. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  77. REMOVE CLUTCH TUBE BOOT (for Manual Transaxle)

  78. REMOVE CLUTCH TUBE BOOT (for Multi-Mode Manual Transaxle)

  79. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  80. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  81. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

    Click here

  82. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click here

  83. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  84. REMOVE CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  85. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

  86. REMOVE CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)

  87. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  88. REMOVE DIFFERENTIAL PRESSURE SENSOR


    1. Remove the differential pressure sensor connector.

    2. A005KCZ

      Disconnect the 2 vacuum transmitting hoses.

    3. Remove the nut and differential pressure sensor.

  89. REMOVE NO. 1 TURBO INSULATOR


    1. A005IV0

      Remove the 3 bolts and the No. 1 turbo insulator.

  90. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    A005KIV

    1. Disconnect the 2 exhaust gas temperature sensor connectors.

    2. Disengage the 2 harness clamps from the No. 2 timing chain cover.

    3. A005MIS

      Disengage the 2 harness clamps from the harness bracket.

    4. A005KNU

      Remove the bolt, the 3 nuts and the exhaust manifold converter sub-assembly.

  91. REMOVE MANIFOLD SUPPORT BRACKET

    A005JHP

    1. Remove the 3 bolts and the manifold support bracket.

  92. REMOVE NO. 2 MANIFOLD SUPPORT BRACKET

    A005JVQ

    1. Remove the 2 bolts and the No. 2 manifold support bracket.

  93. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  94. REMOVE INLET TURBO OIL PIPE SUB-ASSEMBLY

    Click here

  95. REMOVE EXHAUST MANIFOLD

    Click here

  96. REMOVE CYLINDER BLOCK SIDE COVER

    A005HM3

    1. Remove the bolt, the washer plate and the cylinder block side cover.

  97. REMOVE CRANKSHAFT POSITION SENSOR


    1. Disconnect the crankshaft position sensor connector.

    2. A005MH3

      Disengage the crankshaft position sensor connector wire harness clamp from the wire harness bracket.

    3. Remove the 2 bolts and the crankshaft position sensor.

  98. REMOVE FLYWHEEL SUB-ASSEMBLY

    A005GUPE01

    1. Hold the crankshaft with SST.

      SST
      09213-58014
      09330-00021
    2. A005H9R

      Remove the 6 bolts and flywheel.

  99. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A005GP2

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

  100. DISCONNECT ENGINE WIRE

    A005LFWE08
    Text in Illustration
    *a Engine side
    *b Transaxle side

    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.