ENGINE ASSEMBLY REMOVAL


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. 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.

  3. REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear of the No. 1 engine cover. Continue to raise the No. 1 engine cover to detach the 3 clips on the front and side of the No. 1 engine cover and remove the No. 1 engine cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  4. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A01IS0M

      Remove the 3 clips.

    2. Detach the 4 hooks and remove the radiator support opening cover.

  5. 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.

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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

  8. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  9. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)


    1. A01ISZQ

      Detach the wire harness clamp and disconnect the sensor connector.

    2. Remove the bolt and sensor.

    3. Disconnect the 2 vacuum hoses.

  10. REMOVE OUTER COWL TOP PANEL


    1. A01IO5B

      Remove the 9 bolts and outer cowl top panel.

  11. REMOVE FRONT BUMPER COVER

    Click here

  12. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01IOQE

      Remove the 2 clips.

    2. A01IPJ8

      Remove the 4 bolts.

    3. Detach the 2 hooks of the front lower bumper absorber from the installation holes in the body and remove the front lower bumper absorber.

  13. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IRQL

      Remove the 6 bolts and 10 clips.

    2. Remove the No. 1 engine under cover.

  14. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01IOL8

      Remove the 4 clips and No. 2 engine under cover.

  15. REMOVE REAR ENGINE UNDER COVER RH


    1. A01IQ51

      Remove the 5 clips and rear engine under cover RH.

  16. REMOVE REAR ENGINE UNDER COVER LH


    1. A01INGO

      Remove the 5 clips and rear engine under cover LH.

  17. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap and air release plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      A01IUC4E01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Radiator Drain Cock Plug - -

  18. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Install a new gasket and the oil pan drain plug.

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

  19. DRAIN MANUAL TRANSAXLE OIL

    A01IP1ME01
    Text in Illustration
    *1 Filler Plug
    *2 Drain Plug

    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket to drain the manual transaxle oil.

    3. Install a new gasket and the drain plug.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  20. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  21. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01IP71

      Remove the bolt and loosen the nut.

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

  22. REMOVE BATTERY INSULATOR

  23. REMOVE BATTERY

  24. REMOVE BATTERY TRAY

  25. REMOVE BATTERY CARRIER


    1. A01ISD1

      Detach the 2 clamps and disconnect the wire harness.

    2. Remove the 4 bolts and battery carrier.

  26. REMOVE RADIATOR ASSEMBLY

    Click here

  27. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A01IQA7

      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.

  28. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A01IPZC

      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.

  29. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01ISW7

      Slide the clamp and disconnect the No. 2 vacuum transmitting hose assembly from the intake manifold.

  30. REMOVE NO. 3 AIR HOSE


    1. A01ISZ1

      Loosen the 2 hose clamps.

    2. Remove the No. 3 air hose from the No. 2 air tube and diesel throttle body assembly.

  31. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01IOT2

      Detach the clamp and disconnect the mass air flow meter connector.

    2. Slide the clamp and disconnect the PCV hose from the cylinder head cover sub-assembly.

    3. Slide the clamp and disconnect the air cleaner hose assembly from the turbocharger sub-assembly.

    4. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  32. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  33. REMOVE AIR CLEANER CASE


    1. A01ITZL

      Remove the 3 bolts and air cleaner case.

  34. REMOVE FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)


    1. A01IPL7

      Disconnect the 4 fuel hoses.

    2. A01IRKK

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  35. REMOVE FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)


    1. A01IPJP

      Disconnect the 5 fuel hoses.

    2. A01IRKK

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  36. REMOVE FUEL FILTER SUPPORT


    1. A01IQQY

      Raise the lever while pushing the lock on the lever, and disconnect the ECM connector.

      Note

      After disconnecting the connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connector.

    2. A01IQC4

      Disconnect the connector.

    3. Detach the 2 clamps and disconnect the engine wire.

    4. A01INYZ

      Remove the bolt and disconnect the glow relay.

    5. Detach the 2 clamps and disconnect the wire harness.

    6. A01IPPR

      Remove the 3 bolts and fuel filter support.

  37. REMOVE AIR CLEANER BRACKET


    1. A01ITN9

      Remove the 3 bolts and air cleaner bracket.

  38. DISCONNECT HOSES AND CONNECTORS


    1. Remove the engine room No. 1 relay block cover.

    2. Disconnect the current sensor connector.

    3. A01ISG3

      Disconnect the 4 connectors.

    4. Remove the 2 nuts.

    5. Detach the 2 claws and disconnect the engine wire from the engine room No. 1 relay block.

    6. A01IUEL

      Remove the bolt and disconnect the ground cable.

    7. A01IOAN

      Detach the 4 clamps and disconnect the wire harness.

    8. Slide the clamp and disconnect the No. 1 fuel hose from the supply pump assembly.

    9. Slide the clamp and disconnect the No. 2 fuel hose from the No. 2 nozzle leakage pipe.

    10. A01IOEJ

      Slide the clamp and disconnect the vacuum pump hose from the vacuum pump assembly.

  39. DISCONNECT INLET HEATER WATER HOSE


    1. A01IU86

      Slide the clamp and disconnect the inlet heater water hose from the cylinder head sub-assembly.

  40. DISCONNECT OUTLET HEATER WATER HOSE


    1. Slide the clamp and disconnect the outlet heater water hose from the No. 3 water by-pass pipe.

  41. REMOVE INTERCOOLER AIR HOSE


    1. A01IRFKE01
      Text in Illustration
      *1 Retainer

      Loosen the hose clamp and disconnect the intercooler air hose from the No. 1 air tube.

    2. Pull out the retainer and remove the intercooler air hose from the intercooler.

  42. DISCONNECT NO. 1 WATER BY-PASS HOSE


    1. A01IUQB

      Slide the clamp and disconnect the No. 1 water by-pass hose from the No. 4 water by-pass pipe.

  43. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01IQH9

      Remove the 2 pins and disconnect the 2 transmission control cable assemblies from the manual transaxle.

    2. Remove the 2 clips and disconnect the 2 transmission control cable assemblies from the transmission control cable bracket.

  44. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01IQWP

      Remove the 6 bolts and disconnect the clutch release cylinder assembly and clutch flexible hose bracket.

  45. SECURE STEERING WHEEL


    1. A01ITFX

      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.

  46. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A01IPW5

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

  47. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01IQQD

      Remove the bolt.

      Note

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

    2. A01IPG7E01
      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.

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


    1. A01IN1RE08
      Text in Illustration
      *a Clip A
      *b Clip B
      *c Lip

      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.

  49. REMOVE FRONT AXLE SHAFT NUT LH


    1. A01IP5HE01

      Using SST and a hammer, unstake the staked part of the front axle shaft nut.

      SST
      09930-00010

      Note

      Loosen the staked part of the front axle shaft nut completely, otherwise the screw of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle shaft nut.

  50. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  51. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    A01IQIJE04

    1. Remove the nut and disconnect the stabilizer link assembly LH from the front stabilizer bar.

      Tech Tips

      If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.

  52. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  53. REMOVE FRONT AXLE ASSEMBLY LH

    Click here

  54. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01IRMNE01

      Using SST, remove the front drive shaft.

      SST
      09520-00031
      09520-01010

      Note


      • Be careful not to damage the transaxle case oil seal, inboard joint boot or drive shaft dust cover.

      • Be careful not to drop the drive shaft.

  56. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A01IR8P

      Remove the 2 bolts and pull out the drive shaft together with the drive shaft bearing case from the transaxle.

      Note


      • Be careful not to damage the inboard joint boot or drive shaft dust cover.

      • Be careful not to drop the drive shaft.

  57. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. A01INJJ

      Remove the 2 bolts and front lower engine mounting bracket reinforcement.

  58. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01IS2K

      Remove the 4 bolts and front suspension member reinforcement LH.

  59. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01INC5

      Remove the 4 bolts and front suspension member reinforcement RH.

  60. REMOVE FUEL HOSE PROTECTOR


    1. A01IQ9W

      Remove the fuel hose protector from the cylinder head sub-assembly.

  61. INSTALL ENGINE HANGERS


    1. A01IPKAE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

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

      Tech Tips

      Part No.
      No. 1 engine hanger 12281-26040
      No. 2 engine hanger 12282-26010
      Bolt 90105-W0042

      • Insert the claw of the No. 1 engine hanger into the hole of the cylinder head sub-assembly.

      • Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head sub-assembly.

  62. REMOVE ENGINE WITH TRANSAXLE


    1. A01ISCQ

      Remove the bolt and disconnect the cable bracket.

    2. A01IT3W

      for DPF:

      Detach the 3 clamps and disconnect the wire harness.

    3. Set an engine lifter underneath the engine.

      Tech Tips

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

    4. A01IR8D

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

    5. A01IQUU

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

    6. A01ISQ8

      Remove the 6 bolts and front suspension member rear brace RH and front suspension member rear brace LH.

    7. Remove the 2 bolts and front suspension crossmember sub-assembly.

    8. A01IT7H

      Remove the 6 bolts and front crossmember sub-assembly.

    9. Carefully remove the engine with transaxle from the vehicle.

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

  63. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01IOT4E01
      Text in Illustration
      *1 Through Bolt
      *2 Nut

      Remove the through bolt, nut and front engine mounting insulator.

  64. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A01IQL4

      Remove the 3 bolts, 2 nuts and rear engine mounting insulator.

  65. REMOVE NO. 1 AIR TUBE


    1. A01IS5M

      Loosen the hose clamp.

    2. Remove the 2 bolts and No. 1 air tube.

  66. REMOVE STARTER ASSEMBLY


    1. A01INZ3

      Disconnect the starter connector.

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

    3. A01INO6

      Remove the 2 bolts and starter assembly.

  67. REMOVE ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine, and then remove the bracket bolts and engine wire from the engine.

  68. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01IS6T

      Remove the 3 bolts and front engine mounting bracket.

  69. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01IRVA

      Remove the 5 bolts and rear engine mounting bracket.

  70. REMOVE ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. A01INOT

      Remove the 4 bolts and engine mounting bracket LH.

  71. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01ISA9

      Remove the 4 bolts and engine mounting insulator LH.

  72. REMOVE ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. A01IRH7

      Remove the 3 bolts and engine mounting insulator RH.

  73. REMOVE OIL PAN INSULATOR


    1. A01IS9M

      Remove the 2 bolts and oil pan insulator.

  74. REMOVE STIFFENER PLATE RH


    1. A01IQ9A

      Remove the 4 bolts and stiffener plate RH.

  75. REMOVE STIFFENER PLATE LH


    1. A01IN9C

      Remove the 4 bolts and stiffener plate LH.

  76. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  77. REMOVE CLUTCH COVER ASSEMBLY


    1. A01IRLCE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt 180° at a time until the spring tension is released.

      Note

      Be sure to uniformly loosen the bolts 180° at a time according to the order in the illustration.

    3. Remove the set bolts and pull off the clutch cover to remove it.

      Note

      Do not drop the clutch disc.

  78. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc, the pressure plate, and the surface of the flywheel away from oil and foreign matter.

  79. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01IPB5E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A01IP7G

      Using a T55 "TORX" socket wrench, remove the 8 bolts and flywheel sub-assembly.

  80. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine to an engine stand, and remove the sling device and chain block from the engine.

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