ENGINE ASSEMBLY REMOVAL


  1. 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 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 notice before proceeding with work Click here.

  2. 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.

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, 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 }

  6. DRAIN AUTOMATIC TRANSAXLE FLUID


    1. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket, and drain the ATF.

    2. Using a 10 mm hexagon socket wrench, install a new gasket and the drain plug.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  7. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator cap sub-assembly or 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.


    1. Loosen the radiator drain cock plug.

    2. Loosen the cylinder block drain cock plug.

    3. Remove the radiator cap sub-assembly.

      A01EUUEE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Radiator Drain Cock Plug
      *3 Cylinder Block Drain Cock Plug -

      Tech Tips

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

  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  9. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01EVIB

      Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.

    2. A01EYMF

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

  10. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01EX2B

      Remove the 9 clips and cool air intake duct seal.

  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01EX8D

      Remove the 2 nuts and No. 1 engine cover sub-assembly.

  12. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A01EVXG

      Remove the 2 bolts and inlet air cleaner assembly.

  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01EV7D

      Disconnect the vacuum switching valve connector.

    2. Disconnect the 2 vacuum switching valve vacuum hoses.

    3. Disconnect the purge line hose from the 2 clamps.

    4. Disconnect the mass air flow meter connector.

    5. Disconnect the wire harness clamp.

    6. Loosen the 2 bolts and separate the air cleaner cap sub-assembly.

    7. A01EW34

      Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    8. A01EX2PE01
      Text in Illustration
      *1 Air Cleaner Hose Clamp

      Lock the air cleaner hose clamp as shown in the illustration, and disconnect the air cleaner cap sub-assembly from the throttle with motor body assembly.

    9. Remove the air cleaner filter element from the air cleaner case sub-assembly.

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01ESTN

      Disconnect the wire harness clamp.

    2. Remove the 3 bolts and air cleaner case sub-assembly.

  15. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A01EUZ8

      Remove the 2 bolts and No. 2 engine mounting stay RH.

  16. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY


    1. A01EX2T

      Remove the 3 bolts and engine moving control rod sub-assembly.

  17. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH


    1. A01ETCW

      Remove the 3 bolts and No. 2 engine mounting bracket RH.

  18. DISCONNECT UNION TO VACUUM TUBE HOSE


    1. A01EXZL

      Disconnect the union to vacuum tube hose from the intake manifold.

  19. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01ET3P

      Disconnect the wire harness clamp and No. 1 radiator hose.

  20. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01EWNOE01

      Disconnect the No. 2 radiator hose.

  21. DISCONNECT INLET NO. 1 OIL COOLER HOSE


    1. A01EVV4

      Disconnect the inlet No. 1 oil cooler hose from the automatic transaxle assembly.

  22. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE


    1. A01EZ37

      Disconnect the hose clamp and outlet No. 1 oil cooler hose from the automatic transaxle assembly.

  23. DISCONNECT INLET HEATER WATER HOSE


    1. A01EZ30

      Disconnect the breather hose.

    2. A01EWRG

      Disconnect the inlet heater water hose.

  24. DISCONNECT OUTLET HEATER WATER HOSE


    1. A01EWJV

      Disconnect the outlet heater water hose.

  25. REMOVE STARTER ASSEMBLY


    1. A01EWZN

      Disconnect the connector.

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

    3. A01EYMU

      Remove the 2 bolts and starter assembly.

  26. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. A01EUH5

      Pull up the lever and disconnect the ECM connector and 2 wire harness clamps.

    3. A01EUXW

      Disconnect the 4 connectors and remove the nut.

    4. Using a screwdriver, disengage the claw and separate the engine wire.

    5. A01EYRK

      Remove the bolt and disconnect the wire harness clamp.

    6. A01EUA8

      Disconnect the wire harness clamp.

  27. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01ESWW

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

    2. A01EU6S

      Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.

    3. A01EVNJ

      Disconnect the control cable from the control cable support.

  28. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01EXMX

      Disconnect the 2 connectors.

    2. Disengage the 2 clamps.

    3. A01EVAL

      Remove the bolt and bracket.

    4. A01ETB1

      Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor assembly with pulley.

    5. 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 entry of moisture and foreign matter.

  29. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. A01EYDL

      Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor assembly with pulley.

    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 entry of moisture and foreign matter.

  30. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01EXD6

      Remove the No. 1 fuel pipe clamp.

    2. A01EYZLE01
      Text in Illustration
      *1 Fuel Pipe
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-ring
      *5 Retainer
      A01EUL1 Pinch
      A01ETOA Pull

      Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

      Note


      • Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

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

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

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

      • Cover the fuel tube connector and fuel pipe with plastic bags to prevent damage and contamination.

    3. A01EVKX

      Remove the fuel tube sub-assembly from the fuel hose clamp.

  31. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01EYDR

      Disconnect the oxygen sensor connector.

    2. A01EXZP

      Remove the 2 bolts, 2 nuts, 2 compression springs and front exhaust pipe assembly.

    3. Remove the 2 gaskets from the front exhaust pipe assembly and exhaust manifold converter sub-assembly.

  32. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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  33. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  34. SECURE STEERING WHEEL


    1. A01EYAP

      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.

  35. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01EW7UE02
      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.

  36. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A01EYCY

      Remove the flywheel housing under cover.

  37. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A01EYYZ

      Turn the crankshaft to gain access to the removal locations of the 6 drive plate and torque converter assembly setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

  38. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A01EVWP

      Set an engine lifter.

      Text in Illustration
      A01EV1N 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.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from 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 or removed from an engine stand.

    2. A01EWS2

      Remove the 4 bolts, 2 nuts, and frame side rail plate RH and LH.

    3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.

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

      Note


      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

    5. Remove the engine wire from the engine assembly with transaxle.

  39. INSTALL ENGINE HANGERS


    1. A01ETLPE08
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger 12281-28010
      No. 2 engine hanger 12282-28010
      Bolt 91552-B1020

  40. REMOVE V-RIBBED BELT


    1. A01EVVHE01

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

      Note


      • Make sure that SST and other tools are set to the V-ribbed belt tensioner assembly securely.

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

      SST
      09216-42010

    2. Remove the V-ribbed belt from each pulley and slowly return the V-ribbed belt tensioner assembly.

  41. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY


    1. A01EX6G

      Remove the 4 bolts and compressor assembly with pulley.

  42. REMOVE GENERATOR ASSEMBLY


    1. A01EVO2

      Disconnect the connector and wire harness clamp.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the generator wire.

    4. Remove the bolt and wire harness clamp bracket.

    5. A01EWV7

      Remove the 2 bolts and generator assembly.

  43. REMOVE FRONT FRAME ASSEMBLY


    1. A01EVXW

      Remove the nut and separate the engine mounting insulator LH .

    2. A01ESUH

      Remove the bolt and separate the front engine mounting insulator.

    3. A01EVZE

      Remove the nut and separate the engine mounting insulator RH.

    4. Remove the front frame assembly.

    5. Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle on a flat level surface.

      Note


      • Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally.

      • To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.

      • Using an engine sling device and engine lift, secure the engine assembly with transaxle before service.

  44. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01ET8X

      Remove the 3 nuts and front engine mounting insulator.

      Tech Tips

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

  45. REMOVE ENGINE MOUNTING INSULATOR LH


    1. A01EWW6

      Remove the 2 hole plugs from the front frame assembly.

    2. A01EYOB

      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.

  46. REMOVE ENGINE MOUNTING INSULATOR RH


    1. A01EUNL

      Remove the 2 hole plugs from the front frame assembly.

    2. A01EUQR

      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.

  47. REMOVE DRIVE SHAFT BEARING BRACKET


    1. A01EXVW

      Remove the 3 bolts and drive shaft bearing bracket.

  48. REMOVE ENGINE MOUNTING BRACKET RH


    1. A01EYA2

      Remove the 3 bolts and engine mounting bracket RH.

  49. DISCONNECT ENGINE WIRE


    1. A01EXTM

      Remove the bolt and disconnect the 4 connectors, 6 clamps and engine wire from the automatic transaxle assembly.

  50. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY


    1. Using a 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. A01ET9B

      Remove the 9 bolts and automatic transaxle assembly.

      Note

      To prevent damage to the knock pins, do not pry between the automatic transaxle assembly and engine.

  51. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01EXDDE01
      Text in Illustration
      *a Hold

      Using SST, hold the crankshaft pulley.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01EW0Y

      Remove the 8 bolts, the front drive plate spacer, the drive plate and ring gear sub-assembly, and the rear drive plate spacer.

  52. INSTALL ENGINE STAND


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