ENGINE ASSEMBLY REMOVAL

PRECAUTION

CAUTION:

The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

Note

After turning the engine 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.
RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM
1. Turn the A/C switch on.
2. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.
3. Turn the ignition switch off.
4. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.
DISCHARGE FUEL SYSTEM PRESSURE

Click here
ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE FRONT WHEELS
REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
REMOVE ENGINE UNDER COVER RH
REMOVE FRONT FENDER APRON SEAL RH
REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
REMOVE ENGINE UNDER COVER LH
REMOVE FRONT FENDER APRON SEAL LH
DRAIN ENGINE OIL
1. Remove the oil filler cap.
2. Remove the oil drain plug and drain the oil into a container.
3. Clean the oil drain plug.
4. Install the oil drain plug with a new gasket.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }

DRAIN ENGINE COOLANT

Note

Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Loosen the radiator drain cock plug.
Loosen the cylinder block drain cock plug (for Bank 1).
Loosen the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

Remove the radiator cap sub-assembly.

Text in Illustration
*1	Radiator Cap Sub-assembly	*2	Cylinder Block Drain Cock Plug (for Bank 1)
*3	Cylinder Block Drain Cock Plug (for Bank 2, w/ Cylinder Block Drain Cock Plug)	*4	Radiator Drain Cock Plug
*5	Air Drain Cock Plug	-	-

Tech Tips

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

DRAIN AUTOMATIC TRANSAXLE FLUID

Remove the front wheel opening extension pad LH, engine under cover LH and front fender apron seal LH.
Remove the refill plug and gasket from the automatic transaxle assembly.
Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transaxle assembly.

Text in Illustration
*1	No. 1 Transmission Oil Filler Tube
*2	Hexagon Socket Wrench
*a	Overflow Plug Hole

Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle assembly.

Drain automatic transaxle fluid from the automatic transaxle assembly.

Text in Illustration
*1	No. 1 Transmission Oil Filler Tube
*2	Hexagon Socket Wrench
*a	Overflow Plug Hole

Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle assembly.

Torque:: 1.7 N*m { 17 kgf*cm, 15 in.*lbf }

Using a 6 mm hexagon socket wrench, install a new gasket and the overflow plug to the automatic transaxle assembly.

Torque:

40 N*m { 408 kgf*cm, 30 ft.*lbf }
Temporarily install the gasket and refill plug to the automatic transaxle assembly.

REMOVE COOL AIR INTAKE DUCT SEAL
1. Remove the 9 clips and cool air intake duct seal.
REMOVE V-BANK COVER SUB-ASSEMBLY
1. Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the retainer on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.
  
  Note
  
  Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.
REMOVE INLET NO. 2 AIR CLEANER
1. Disconnect the 2 wire harness clamps and vacuum hose clamp.
2. Remove the 2 bolts and inlet No. 2 air cleaner.
REMOVE AIR CLEANER CAP SUB-ASSEMBLY
1. Disconnect the mass air flow meter connector and wire harness clamp.
2. Disconnect the 3 hoses.
3. Separate the ventilation hose.
4. Loosen the hose clamp and separate the air cleaner cap sub-assembly from the throttle with motor body assembly.
5. Release the 2 clamps and remove the air cleaner cap with hose.
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
1. Disconnect the wire harness clamp, connector, vacuum hose and No. 1 fuel vapor feed hose.
2. Remove the 2 bolts and air cleaner case sub-assembly.
REMOVE BATTERY
1. Disconnect the positive (+) cable from the positive (+) battery terminal.
2. Loosen the nut and remove the bolt.
3. Remove the battery and battery tray.
REMOVE INLET NO. 1 AIR CLEANER
1. Disengage the pin and remove the inlet No. 1 air cleaner.
REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY
1. Disengage the claw and disconnect the 2 vacuum hoses.
2. Remove the 2 bolts and intake air resonator sub-assembly.
REMOVE NO. 2 ENGINE MOUNTING STAY RH
1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
REMOVE ENGINE MOVING CONTROL ROD BRACKET
1. Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.
REMOVE ENGINE MOVING CONTROL ROD
1. Remove the bolt and engine moving control rod from the engine moving control rod bracket.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine moving control rod is necessary.
SEPARATE EARTH WIRE
1. Remove the 2 bolts and separate the earth wire from the engine assembly.
DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
1. Disconnect the No. 1 fuel vapor feed hose.
DISCONNECT UNION TO CHECK VALVE HOSE
1. Disconnect the union to check valve hose from the brake booster.
DISCONNECT NO. 1 RADIATOR HOSE
1. Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.
2. Disconnect the No. 1 radiator hose.
DISCONNECT NO. 2 RADIATOR HOSE
1. Disconnect the No. 2 radiator hose.
DISCONNECT OUTLET NO. 1 OIL COOLER HOSE
1. Disconnect the outlet No. 1 oil cooler hose from the automatic transaxle assembly.
DISCONNECT INLET NO. 1 OIL COOLER HOSE
1. Disconnect the inlet No. 1 oil cooler hose from the automatic transaxle assembly.
DISCONNECT INLET HEATER WATER HOSE
1. Disconnect the inlet heater water hose.
DISCONNECT OUTLET HEATER WATER HOSE
1. Disconnect the outlet heater water hose.
REMOVE STARTER ASSEMBLY
1. Disconnect the starter connector.
2. Remove the terminal cap.
3. Remove the nut and disconnect the starter wire.
4. Remove the 2 bolts and starter assembly.
DISCONNECT ENGINE WIRE
1. Remove the No. 1 relay block cover.
2. Remove the 2 nuts and disconnect the wire clamp.
3. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
4. Disconnect the 4 connectors.
5. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
6. Pull up the lever to disconnect the ECM connector.
7. Disconnect the 2 wire clamps.
REMOVE AIR CLEANER BRACKET
1. Disconnect the 2 wire clamps.
2. Remove the bolt and No. 1 air cleaner bracket from the battery carrier.
SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
1. Move the shift lever to N.
2. Disconnect the wire harness clamp.
3. Remove the nut from the transmission control shaft lever.
4. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.
DISCONNECT FUEL MAIN TUBE
1. Remove the No. 1 fuel pipe clamp.
2. Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.
  
  Text in Illustration
  
  Push
  
  Pull
  Note
  
  Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
  
  Do not use any tools to separate the pipe and connector.
  
  Do not forcefully bend or twist the nylon tube.
  
  Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
  
  Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
  
  If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Disconnect the 3 connectors.
2. Disengage the 2 clamps.
3. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor and magnetic clutch.
4. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
1. Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor and magnetic clutch.
2. Remove the O-ring from the No. 1 cooler refrigerant suction hose.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
1. Remove the 2 nuts and No. 1 exhaust pipe support bracket (for Front Side).
REMOVE FRONT EXHAUST PIPE ASSEMBLY
1. Disconnect the 2 wire harnesses from the clamp.
2. Disconnect the 2 heated oxygen sensor connectors.
3. Remove the 2 bolts and No. 1 exhaust pipe support bracket (for Rear Side).
4. Remove the 4 bolts, 4 nuts and front exhaust pipe assembly.
5. Remove the 3 gaskets from the front exhaust pipe assembly.
SECURE STEERING WHEEL
1. Text in Illustration
  
  *1 Protective Tape
  
  Using SST, secure the steering link assembly in a vise.
  
  SST
  
  09612-00012
  
  Tech Tips
  
  Tape SST before use.
SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
1. Text in Illustration
  
  *a Matchmark
  
  Put matchmarks on the steering intermediate shaft assembly and steering link assembly.
2. Remove the bolt.
3. Separate the steering intermediate shaft assembly from the steering link assembly.
REMOVE FRONT AXLE SHAFT NUT LH
1. Using SST and a hammer, release the staked part of the front axle shaft nut.
  
  SST
  
  09930-00010
  
  Note
  
  Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.
2. While applying the brakes, remove the front axle shaft nut.
REMOVE FRONT AXLE SHAFT NUT RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
1. for Steel Type:
  1. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.
    
    If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt.
2. for Aluminum Type:
  1. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.
    
    If the ball joint turns together with the nut, use a wrench to hold the stud bolt.
SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT SPEED SENSOR LH
1. Remove the bolt, disengage the clamp and separate the front speed sensor and front flexible hose.
  
  Note
  
  Be sure to separate the front speed sensor from the front shock absorber assembly completely.
2. Remove the bolt and front speed sensor from the steering knuckle.
  Note
  
  Prevent foreign matter from contacting the sensor tip.
  
  Be careful not to damage the front speed sensor.
  
  Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.
SEPARATE FRONT SPEED SENSOR RH

Tech Tips

Perform the same procedure as for the LH side.

Text in Illustration
	Push
	Pull

Text in Illustration
*1	Protective Tape

Text in Illustration
*a	Matchmark

SEPARATE TIE ROD ASSEMBLY LH

Remove the cotter pin and nut.
Install SST to the tie rod assembly LH.

SST

09960-20010 ( 09961-02060 )

Note

Make sure that the lower ends of the tie rod assembly LH and SST are aligned.
Secure SST using a string.

Note

Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.

Using SST, separate the tie rod assembly LH from the steering knuckle.

Text in Illustration
*1	Center Nut	-	-
*a	String	*b	Grease Application Area
	Place the wrench here.	-	-

SST: 09960-20010 ( 09961-02010 )

CAUTION:

Apply grease to the bolt threads and the tip of SST.

Note

Install SST with the center nut so that A and B shown in the illustration are parallel. Otherwise, the dust cover may be damaged.

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

Do not damage the front disc brake dust cover.

Do not damage the ball joint dust cover.

Do not damage the steering knuckle.

SEPARATE TIE ROD ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH
1. Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.
SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT DRIVE SHAFT ASSEMBLY
1. Text in Illustration
  
  *a Matchmark
  
  Put matchmarks on the front drive shaft assembly and the front axle hub sub-assembly.
2. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.
  
  If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer.
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using SST, remove the front drive shaft assembly LH.
  
  SST
  
  09520-00031
  
  09520-01010
  Note
  
  Do not damage the transaxle case oil seal.
  
  Do not damage the front axle inboard joint boot.
  
  Do not drop the front drive shaft assembly LH.
REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH
1. Using a screwdriver, remove the front drive shaft hole snap ring LH.
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
1. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.
2. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.
  Note
  - Do not damage the front transaxle case oil seal.
  - Do not damage the front axle inboard joint boot.
  - Do not drop the front drive shaft assembly RH.
3. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH.
REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
1. Remove the bolt and No. 1 exhaust pipe support bracket.
REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
1. Remove the 2 bolts and No. 1 exhaust pipe support bracket sub-assembly.
REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT
1. Turn the crankshaft to gain access to the removable locations of the 6 torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.
  
  Tech Tips
  
  There will be one black colored bolt.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine lifter.
  
  Text in Illustration
  
  Attachment Installation Position
  Note
  
  Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
  
  Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
  
  To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
  
  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.
2. Remove the 4 bolts, 2 nuts and frame side rail plates RH and LH.
3. Remove the 4 bolts, 2 nuts and front suspension member rear braces RH and LH.
4. Operate the engine lifter, then remove the engine assembly 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.
5. Install the engine hangers Click here.
REMOVE V-RIBBED BELT
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 its holes, and then insert a 5 mm hexagon wrench into the holes to fix the V-ribbed belt tensioner.
REMOVE GENERATOR ASSEMBLY
1. Remove the terminal cap.
2. Remove the nut and disconnect the wire harness from terminal B.
3. Disconnect the generator connector from the generator assembly.
4. Remove the bolt and disconnect the wire harness clamp.
5. Remove the 2 bolts.
6. Remove the 2 bolts and generator assembly.
7. Disconnect the wire harness clamp and remove the generator bracket.
REMOVE COMPRESSOR AND MAGNETIC CLUTCH
1. Remove the 4 bolts and compressor and magnetic clutch and bracket.
REMOVE FRONT FRAME ASSEMBLY
1. Disconnect the oil pressure switch connector and 2 clamps.
2. Disconnect the 2 clamps and vacuum switching valve connector.
3. Remove the bolt and disconnect the front engine mounting insulator.
4. Remove the nut and disconnect the engine mounting insulator LH.
5. Remove the nut and disconnect the engine mounting insulator RH.
6. Remove the front frame assembly.
REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY
1. Remove the 3 nuts and front engine mounting insulator assembly.
  
  Tech Tips
  
  Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary.
REMOVE ENGINE MOUNTING INSULATOR LH
1. Remove the 2 hole plugs from the front frame assembly.
2. Remove the 3 nuts and engine mounting insulator LH.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
REMOVE ENGINE MOUNTING INSULATOR RH
1. Remove the 2 hole plugs from the front frame assembly.
2. Remove the 3 nuts and engine mounting insulator RH.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
REMOVE ENGINE WIRE
1. Remove the engine wire from the engine with transaxle.
REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
1. Using the transmission jack attachment, set the automatic transaxle assembly on a transmission jack.
  Note
  - Secure the automatic transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.
  - To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the automatic transaxle assembly.
  - Hold the engine assembly with a suitable adapter, such as a rope, during the operation.
2. Remove the 11 bolts and transaxle.
  
  Note
  
  To prevent damage to the knock pins, do not pry between the transaxle and engine.
REMOVE ENGINE MOUNTING BRACKET RH
1. Remove the 3 bolts and engine mounting bracket RH.
REMOVE DRIVE SHAFT BEARING BRACKET
1. Remove the 3 bolts and drive shaft bearing bracket.
REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-70011 ( 09213-70020 )
  
  09330-00021
2. Remove the 8 bolts, front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer.
INSTALL ENGINE ON ENGINE STAND
1. Install the engine onto an engine stand with the bolts.