ENGINE ASSEMBLY REMOVAL

Note

for Manual Transaxle:

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.


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  3. REMOVE FRONT BUMPER COVER


    1. Remove the front bumper cover Click here.

  4. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator Click here.

  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. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01IRTL

      Remove the 4 bolts and front lower bumper absorber.

  8. REMOVE REAR ENGINE UNDER COVER RH


    1. A01IP88

      Remove the 5 clips and under cover RH.

  9. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and under cover.

  10. REMOVE CENTER NO. 4 ENGINE UNDER COVER


    1. A01IT0F

      Remove the 2 clips and under cover.

  11. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01IOL8

      Remove the 4 clips and under cover.

  12. 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 while the engine and radiator are still hot.

      Pressurized, hot engine coolant and steam may be released and cause serious burns.

      A01INZOE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Radiator Drain Cock Plug

  13. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the 3 clips and open the oil pan drain service cover.

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

  14. DRAIN MANUAL TRANSAXLE OIL


    1. A01IQMNE02
      Text in Illustration
      *1 Filler Plug

      Remove the filler plug and gasket.

    2. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket to drain the manual transaxle oil.

      Text in Illustration
      *2 Drain Plug

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

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  15. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID


    1. A01IQT6

      Remove the refill plug and gasket from the continuously variable transaxle assembly.

    2. A01INWW

      Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the continuously variable transaxle assembly.

    3. A01IRH8E01
      Text in Illustration
      *1 No. 1 Transmission Oil Filler Tube

      Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the transaxle oil (CVT) pan sub-assembly.

      Tech Tips

      Removing the No. 1 transmission oil filler tube will drain all oil in the transaxle oil (CVT) pan sub-assembly.

    4. Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the transaxle oil (CVT) pan sub-assembly.

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

    5. Using a 6 mm hexagon socket wrench, temporarily install the overflow plug and gasket to the continuously variable transaxle assembly.

      Tech Tips

      Reuse the old gasket as the overflow plug will be removed again to adjust the fluid level.

    6. Temporarily install the gasket and refill plug to the continuously variable transaxle assembly.

      Tech Tips

      Reuse the old gasket as the refill plug will be removed again to adjust the fluid level.

  16. DISCONNECT RADIATOR RESERVOIR ASSEMBLY


    1. A01IQ7P

      Remove the 2 bolts and disconnect the radiator reservoir.

    2. Remove the grommet from the radiator reservoir.

  17. REMOVE V-RIBBED BELT


    1. A01IRTVE01
      Text in Illustration
      *a 5 mm Hexagon Wrench
      *b Hole
      *c Gap

      Attach a wrench to the hexagonal portion (A) or (B) of the V-ribbed belt tensioner assembly as shown in the illustration.

    2. Rotate the V-ribbed belt tensioner assembly clockwise to align the hole with the gap, and then insert a 5 mm hexagon wrench into the hole and gap to secure the V-ribbed belt tensioner assembly.

    3. Remove the V-ribbed belt from the V-ribbed belt tensioner assembly.

  18. REMOVE GENERATOR ASSEMBLY


    1. A01IN06

      Remove the terminal cap.

    2. Remove the nut and disconnect the wire harness from terminal B.

    3. Disconnect the connector and detach the wire harness clamp.

    4. A01IP6F

      Remove the 3 bolts, No. 2 generator bracket and generator assembly.

    5. A01IQ3U

      Remove the bolt and wire harness clamp bracket.

  19. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01IS9V

      Disconnect the radiator hose from the water inlet.

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


    1. A01INHK

      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.

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


    1. A01IQDO

      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.

  22. DISCONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01IO70

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. A01IT87

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the compressor assembly with pulley.

  23. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01ISEG

      Disconnect the mass air flow meter connector.

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

    3. A01IP4V

      Disconnect the 2 clamps.

    4. A01IPUC

      Disconnect the PCV hose.

    5. Loosen the band and remove the air cleaner cap.

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01IPXX

      Detach the wire harness clamp from the air cleaner case.

    2. Remove the 3 bolts and air cleaner case.

  25. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01IQN6E01

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

    2. Remove the bolt and loosen the nut.

    3. Remove the battery clamp.

  26. REMOVE BATTERY

  27. REMOVE BATTERY TRAY

  28. REMOVE BATTERY CARRIER


    1. A01INC1

      Disconnect the 2 wire harness clamps from the battery carrier.

    2. Remove the 2 bolts and disconnect the radiator pipe from the battery carrier.

    3. A01IN2I

      Remove the 4 bolts and battery carrier.

  29. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


    1. A01IOZW

      Remove the 2 clips and disconnect the 2 cables from the transaxle.

    2. A01IRNL

      Remove the 2 clips and disconnect the 2 cables from the control cable bracket.

    3. A01IQ5P

      Remove the nut and disconnect the control cable.

  30. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


    1. A01IPMS

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

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

    3. A01ISQ9

      Remove the bolt and separate the transmission control cable support.

  31. DISCONNECT CLUTCH HOSE (for Manual Transaxle)


    1. A01IO4L

      Using a 10 mm union nut wrench, disconnect the clutch hose from the flexible hose tube.

    2. Remove the clip and disconnect the clutch hose.

  32. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01IT99

      for CVT:

      Disconnect the No. 1 breather plug from the clamp.

    2. A01IS22

      Disconnect the radiator hose from the cylinder head.

  33. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01IUDM

      Release the claw and remove the No. 1 fuel pipe clamp.

    2. A01IUAI

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

      Note


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

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

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

      • Do not forcibly bend, kink or twist 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 to release them.

  34. DISCONNECT HEATER WATER HOSE


    1. A01IO46

      Disconnect the 2 heater water hoses.

  35. DISCONNECT WIRE HARNESS AND HOSE


    1. A01IRS1E01
      Text in Illustration
      *a Lock
      *b Push

      Disconnect the clamp and ECM connector.


      1. Raise the lever while pushing the locks on the levers, 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. A01IUJH

      Remove the 2 nuts from the engine room No. 1 relay block.

    3. Disconnect the 3 engine room No. 1 relay block connectors.

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

    5. A01IQ1O

      Disconnect the battery current sensor connector.

    6. Remove the 2 bolts and disconnect the clamp and engine wire.

    7. A01IR5Y

      Remove the bolt and disconnect the engine wire.

    8. A01ITLG

      Disconnect the connector tube hose

    9. A01ITMZ

      Disconnect the vacuum hose.

  36. SECURE STEERING WHEEL ASSEMBLY


    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.

  37. 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.

  38. 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.

  39. DISCONNECT 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.

  40. REMOVE FRONT FLOOR CENTER BRACE

    A01IP00

    1. Remove the 4 bolts and front floor center brace.

  41. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Detach the clamp and disconnect the heated oxygen sensor wire harness.

    2. Disconnect the heated oxygen sensor connector.

    3. A01ISEX

      Remove the 2 bolts and 2 compression springs.

    4. A01IRWB

      Remove the 2 bolts and 2 compression springs.

    5. Remove the 3 exhaust pipe supports and front exhaust pipe assembly.

  42. 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.

  43. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedures described for the LH side.

  44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH


    1. A01IOOVE03

      Remove the nut and disconnect the stabilizer link assembly from the front shock absorber with coil spring.

      Tech Tips

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

  45. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedures described for the LH side.

  46. REMOVE FRONT AXLE ASSEMBLY LH


    1. Remove the front axle assembly LH Click here.

  47. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedures described for the LH side.

  48. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01IRSDE01

      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.

  49. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  50. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. A01IRUK

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

  51. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)


    1. A01INI7E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-54015
      09330-00021

      Tech Tips

      Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-00850 (quantity: 2)

    2. A01IOU2

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

  52. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01IQC2

      Remove the 4 bolts and front suspension member reinforcement LH.

  53. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01IOXU

      Remove the 4 bolts and front suspension member reinforcement RH.

  54. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A01ITDM

      Remove the bolt and nut.

      Tech Tips

      While holding the nut in place, loosen the bolt.

    2. Remove the front engine mounting insulator from the front engine mounting bracket.

    3. A01IOLA

      Remove the 4 bolts and front crossmember.

  55. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set an engine lifter underneath the engine.

      Note

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

    2. A01IQ7T

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

    3. A01IPE5

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

    4. A01IPWQ

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

    5. A01IRM4

      Remove the 2 bolts and front suspension crossmember.

    6. Operate the engine lifter and slowly remove the engine 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.

  56. INSTALL ENGINE HANGER


    1. A01IQVS

      Disconnect the air fuel ratio sensor connector and remove the bolt and air fuel ratio sensor bracket.

    2. A01IQPBE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050

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

  57. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01IPF2

      Remove the bolt and front suspension crossmember from the engine.

  58. REMOVE STARTER ASSEMBLY


    1. Open the terminal cap.

    2. A01IPMOE01

      Remove the nut and disconnect the starter wire.

    3. Disconnect the connector.

    4. Remove the 2 bolts and starter.

  59. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. A01IN7N

      Remove the flywheel housing side cover from the cylinder block.

  60. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. Remove the manual transaxle assembly Click here.

  61. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. Remove the continuously variable transaxle assembly Click here.

  62. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    A01INYHE02
    Text in Illustration
    *1 Matchmark

    1. Put matchmarks on the clutch cover assembly and flywheel sub-assembly.

    2. Loosen each set bolt one turn at a time in the order shown in the illustration until the spring tension is released.

    3. Remove the set bolts and pull off the clutch cover assembly.

      Note

      Do not drop the clutch disc assembly.

  63. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

  64. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)


    1. A01IRT9E01

      Using SST, hold the crankshaft.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

    2. A01ITRW

      Remove the 8 bolts and flywheel.

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


    1. Remove the clutch release with bearing cylinder assembly Click here.

  66. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)


    1. A01IRT9E01

      Using SST, hold the crankshaft.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

    2. A01IU7Y

      Remove the 8 bolts, rear spacer, drive plate and front spacer.

  67. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  68. INSTALL ENGINE ON ENGINE STAND


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

    2. Remove the 2 bolts and 2 engine hangers.

  69. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A01IOJQ

    1. Remove the 2 bolts and front engine mounting insulator.

  70. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A01IQ5G

    1. Remove the 2 bolts, 2 nuts and engine mounting insulator.

  71. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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

    A01IU19

    1. Disconnect the cooler pipe clamp.

    2. Remove the 2 bolts, nut and 2 cooler pipe brackets.

    3. A01IOMY

      Remove the 3 bolts and engine mounting insulator.

  72. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

    Tech Tips

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

    A01IRY3

    1. Remove the 4 bolts and engine mounting insulator.