ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

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. After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. DRAIN COOLANT

    Click here

  4. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  5. REMOVE FRONT WHEELS

  6. REMOVE ENGINE UNDER COVER LH


    1. A005MJV

      Remove the 3 screws and the 3 bolts.

    2. Remove the engine under cover LH.

  7. REMOVE ENGINE UNDER COVER RH


    1. A005LB0

      Remove the screw and the 2 bolts.

    2. Remove the engine under cover RH.

  8. REMOVE BATTERY


    1. A005I34

      Disconnect the cable from the positive (+) battery terminal.

    2. Loosen the 2 nuts, and remove the battery carrier clamp.

    3. Remove the battery.

  9. REMOVE BATTERY TRAY


    1. A005K18

      Remove the battery tray.

  10. REMOVE FAN AND GENERATOR V BELT

    Click here

  11. REMOVE AIR CLEANER ASSEMBLY


    1. A005GDM

      Disengage the clamp and disconnect the intake mass air flow meter connector.

    2. A005IK2

      Disengage the guide and 2 clips and disconnect the fuel vapor feed hose assembly.

    3. A005MBD

      Disengage the wire harness clamp and disconnect the No. 1 vacuum switching valve connector and the No. 2 fuel vapor feed hose.

    4. A005LMC

      Loosen the air cleaner hose clamp.

    5. Disengage the clamp and remove the air cleaner cap and air cleaner hose.

    6. A005IDX

      Remove the air cleaner element.

    7. A005KJA

      Remove the 2 bolts and the air cleaner case with air cleaner inlet.

  12. REMOVE AIR CLEANER BRACKET

    A005M7K

    1. Disengage the wire harness clamp from the air cleaner bracket.

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

  13. REMOVE BATTERY CARRIER

    A005H7M

    1. Disengage the 7 wire harness clamps and separate the wire harness from the battery carrier.

    2. Remove the 5 bolts and remove the battery carrier.

  14. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. A005IA0

      Loosen the 2 hose clamps and remove the fuel vapor feed hose assembly.

  15. DISCONNECT NO. 3 RADIATOR HOSE


    1. A005LHE

      Loosen the hose clamp and disconnect the No. 3 radiator hose from the water filler sub-assembly.

  16. DISCONNECT RADIATOR RESERVOIR TANK HOSE

    A005H8D

    1. Disconnect the radiator reservoir tank hose from the water filler sub-assembly.

  17. DISCONNECT NO. 2 RADIATOR HOSE


    1. A005H76

      Loosen the hose clamp and disconnect the No. 2 radiator hose from the water inlet.

  18. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  19. REMOVE NO. 2 FUEL PIPE CLAMP


    1. A005LYU

      Disengage the claw and remove the No. 2 fuel pipe clamp.

  20. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A005HCKE01
      Text in Illustration
      *1 Retainer
      A005GO2 Pinch
      A005IBX Pull

      Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.

      Note


      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, twist or turn the nylon tube.

      • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.

      • If the fuel tube connector and pipe are stuck, push and pull them to release them.

  21. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A005IXT

      Loosen the clip and remove the union to check valve hose.

  22. DISCONNECT OUTLET HEATER WATER HOSE A


    1. A005HK2

      Loosen the clip and remove the outlet heater water hose A.

  23. DISCONNECT INLET HEATER WATER HOSE A


    1. A005I3J

      Loosen the clip and remove the inlet heater water hose A.

  24. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY


    1. Disconnect the connector.

    2. A005J95

      Remove the 4 bolts and the separate the compressor assembly with pulley.

      Tech Tips

      It is not necessary to completely remove the compressor assembly with pulley. With the hoses connected to the compressor assembly with pulley, hang the compressor assembly with pulley on the vehicle body with a rope.

      A005K42

  25. DISCONNECT ENGINE WIRE


    1. A005IKV

      Pull up the lever and disconnect the connector from the ECM.

    2. A005K7U

      Disconnect the 2 connectors and disengage the 3 clamps from the engine room junction block, and disconnect the wire harness.

    3. A005HYJ

      Disconnect the 2 connectors from the positive (+) battery terminal.

    4. A005L9J

      Remove the bolt and separate the transaxle earth wire of the engine wire.

    5. Check that the engine wire is disconnected between the body and engine assembly with transaxle.

  26. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  27. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  28. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  29. REMOVE REAR CONSOLE BOX

    Click here

  30. DISCONNECT HEATED OXYGEN SENSOR

    Click here

  31. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  33. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  34. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A005LUK

      Remove the flywheel housing under cover.

  35. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A005IZOE01

      Use SST to hold the crankshaft pulley in place.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

      Note

      Be careful not let SST slip during the work.

    2. A005IMX

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

  36. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A005KAE

      Place height adjustment or plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle.

      Text in Illustration
      A005HNR Attachment Placement Positions

      Note


      • Place the height adjustment or plate lift attachments so that the engine assembly with transaxle is level.


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

      • To prevent deformation of the No. 2 oil pan sub-assembly, never set any attachments against the No. 2 oil pan sub-assembly of the engine assembly with transaxle.

      • To prevent deformation of the transaxle oil pan sub-assembly, never set any attachments against the transaxle oil pan sub-assembly of the continuously variable transaxle.

    2. A005IT6

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

      Text in Illustration
      A005GO2 Bolt
      A005IBX Nut
    3. A005KUY

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

      Tech Tips

      While fixing the nut in place, loosen and remove the bolt.

    4. A005JTA

      Remove the 6 bolts shown in the illustration.

    5. Operate the engine lifter and slowly remove the engine assembly with transaxle from the vehicle.

      Note

      When removing the engine assembly with transaxle, be careful not to damage any wire harnesses or the steering shaft.

  37. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH


    1. A005HLR

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

      Tech Tips

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

  38. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR


    1. A005M57

      Remove the 5 bolts and the transverse engine engine mounting insulator.

      Tech Tips

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

  39. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A005KY8

      Remove the bolt and the wire harness clamp bracket.

  40. INSTALL ENGINE HANGER


    1. A005K9UE03
      Text in Illustration
      *a Front side
      *b Rear side

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

      Torque:
      44 N*m  { 448 kgf*cm, 32 ft.*lbf }
      Part Name Part Number
      Engine Hanger 12281-21010
      Bolt 91642-81025

  41. REMOVE VENTILATION HOSE


    1. A005HL9

      Loosen the 2 clips and remove the ventilation hose.

  42. REMOVE ENGINE WIRE


    1. A005KBF

      Disconnect the 2 ground bolts.

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

  43. SECURE ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note

      Make sure that the sling angle is correct to prevent the engine assembly with transaxle and engine hangers from being damaged or deformed.

    2. To enable removal of the engine assembly with transaxle, adjust the positions of the height adjustment or plate lift attachments and set them in place.

      A005IR7E01
      Text in Illustration
      *1 Plate Lift Attachment - -
      A005HNR Attachment Placement Positions - -

      Note


      • Place the height adjustment or plate lift attachments so that the engine assembly with transaxle is level.


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

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly.

      • To prevent the transaxle oil pan subassembly from deforming, do not place any attachments under the drain plug or oil pan of the continuously variable transaxle.

    3. A005ILP

      Using a rope or belt, secure the engine assembly with transaxle to the engine lifter.

      Note


      • Set the engine assembly with transaxle so that it is horizontal.

      • Do not tighten the rope or belt with a tightening mechanism any more than necessary.

  44. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  45. REMOVE STARTER ASSEMBLY

    Click here

  46. DISCONNECT WATER BY-PASS HOSE

    Click here

  47. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    Click here

  48. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  49. 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.