ENGINE ASSEMBLY REMOVAL

CAUTION:

As the engine assembly with transaxle assembly 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.


  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. A01IRDDE01

      Lift the No. 1 engine cover to detach the 4 clips in the order shown in the illustration and remove the No. 1 engine cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

  4. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A01IPK0

      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 OUTER COWL TOP PANEL


    1. A01IO5B

      Remove the 9 bolts and outer cowl top panel.

  10. REMOVE FRONT BUMPER COVER

    Click here

  11. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01ISFZ

      Remove the 4 bolts.

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

  12. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IR30

      Remove the 6 bolts and 11 clips.

    2. Remove the No. 1 engine under cover.

  13. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01IOL8

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

  14. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and rear engine under cover LH.

  15. REMOVE REAR ENGINE UNDER COVER RH


    1. Remove the 5 clips and rear engine under cover RH.

  16. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the reservoir cap and air release valve 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 and drain the engine coolant.

      A01IUCQE01
      Text in Illustration
      *1 Reservoir Cap *2 Air Release Valve
      *3 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 reservoir cap.

  17. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    2. A01IOM2

      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:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  18. DRAIN MANUAL TRANSAXLE OIL


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

      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 }

  19. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  20. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01ININ

      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.

  21. REMOVE BATTERY INSULATOR

  22. REMOVE BATTERY

  23. REMOVE BATTERY TRAY

  24. REMOVE BATTERY CARRIER


    1. A01IQXM

      Detach the 2 clamps and disconnect the engine wire.

    2. Remove the 4 bolts and battery carrier.

  25. REMOVE RADIATOR ASSEMBLY

    Click here

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


    1. A01IT62

      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.

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


    1. A01IRMB

      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.

  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY


    1. A01IUFHE01
      Text in Illustration
      *1 Retainer

      Detach the clamp and disconnect the mass air flow meter sub-assembly connector.

    2. Detach the clamp and disconnect the vacuum hose from the air cleaner hose assembly.

    3. Detach the clamp and disconnect the No. 1 fuel hose from the air cleaner hose assembly.

    4. Detach the clamp and disconnect the No. 2 fuel hose from the air cleaner hose assembly.

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

    6. Release the retainer and disconnect the air cleaner hose assembly from the turbocharger sub-assembly as shown in the illustration.

    7. Detach the 2 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01IN4S

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

  31. REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A01ISWY

      Slide the clamp and disconnect the water by-pass hose assembly from the radiator reservoir assembly.

    2. Slide the clamp and disconnect the No. 2 water by-pass hose assembly from the radiator reservoir assembly.

    3. Remove the 2 bolts and radiator reservoir assembly.

  32. REMOVE WATER BY-PASS HOSE ASSEMBLY


    1. A01IQ76

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 1 air tube assembly.

    2. A01IU9M

      Remove the water by-pass hose assembly from the water by-pass pipe.

  33. REMOVE RADIATOR HOSE SUB-ASSEMBLY


    1. A01INY3

      Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 air tube assembly.

    2. A01IRTQ

      Remove the No. 1 radiator hose sub-assembly from the water outlet.

  34. DISCONNECT VACUUM HOSE


    1. A01INDL

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

  35. DISCONNECT FUEL HOSE


    1. A01ISC6

      Disconnect the fuel hose from the fuel feed pipe sub-assembly.

  36. DISCONNECT NO. 2 FUEL HOSE


    1. Disconnect the No. 2 fuel hose from the fuel feed pipe sub-assembly.

  37. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. A01IR13

      Slide the clamp and disconnect the water hose sub-assembly from the No. 1 air tube assembly.

  38. DISCONNECT INLET HEATER WATER HOSE


    1. Slide the clamp and disconnect the inlet heater water hose from the No. 1 air tube assembly.

  39. DISCONNECT HOSES AND CONNECTORS


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

    2. A01IN58

      Disconnect the 2 connectors.

    3. Remove the 2 nuts.

    4. Detach the 2 claws to disconnect the engine wire from the No. 1 engine room relay block.

    5. A01IN7G

      Remove the bolt to disconnect the ground cable.

  40. REMOVE FUEL FILTER ASSEMBLY


    1. A01IP76

      Remove the 2 nuts and No. 1 fuel filter protector.

    2. Remove the No. 2 fuel pipe clamp from the No. 1 fuel hose.

    3. A01IN1A

      Disconnect the No. 1 fuel hose and No. 3 fuel hose from the fuel filter assembly Click here.

    4. A01INJU

      Disconnect the connector from the fuel filter assembly.

    5. Remove nut and fuel filter assembly from the fuel filter support.

    6. A01IU9E

      Remove the bolt and fuel filter cover from the fuel filter assembly.

  41. REMOVE FUEL FILTER SUPPORT


    1. A01IPQ9

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

      Note

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

    2. A01IQUE

      Disconnect the connector.

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

    4. A01IPBU

      Detach the clamp to disconnect the wire harness.

    5. Remove the 3 bolts and fuel filter support.

  42. REMOVE AIR CLEANER BRACKET


    1. A01IQ3J

      Remove the 3 bolts and air cleaner bracket.

  43. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01IU7W

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

    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. A01ITAS

      Remove the 4 bolts and disconnect the clutch release cylinder assembly with 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


    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.

  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 assembly LH.

      SST
      09520-01010
      09520-24010   ( 09520-32040 )

      Note


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

      • Be careful not to drop the front drive shaft assembly LH.

  56. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A01IQNA

      Using an E12 ''TORX'' socket wrench, remove the 2 bolts and pull out the front drive shaft assembly RH.

      Note


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

      • Be careful not to drop the front drive shaft assembly RH.

  57. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. A01INCI

      Using a screwdriver, remove the front drive shaft hole snap ring LH.

      Note

      Be careful not to damage the spline of the front drive inboard joint LH.

  58. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. A01IQ2O

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

  59. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01IOVF

      Remove the 4 bolts and front suspension member reinforcement LH.

  60. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01IQDX

      Remove the 4 bolts and front suspension member reinforcement RH.

  61. REMOVE ENGINE WITH TRANSAXLE


    1. A01IQWN

      Remove the bolt to disconnect the cable bracket.

    2. Set an engine lifter underneath the engine assembly.

      Note


      • Place wooden blocks or plate lift attachments so that the engine assembly is level.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan sub-assembly of the engine assembly or transaxle assembly as doing so may deform the oil pan sub-assembly.

    3. A01IQHU

      Detach the clamp and disconnect the air conditioner tube and accessory assembly.

    4. Detach the 2 clamps and disconnect the suction pipe sub-assembly.

    5. A01ING4

      Remove the 4 bolts, 3 nuts and engine mounting insulator RH.

    6. A01IOLO

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

      Tech Tips

      While holding the bolt in place, loosen the nut.

    7. A01IONK

      Remove the through bolt and nut to disconnect the front engine mounting insulator.

    8. A01IO1O

      Remove the 4 bolts and front crossmember sub-assembly.

    9. A01ISFC

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

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

    11. Carefully remove the engine assembly with transaxle assembly from the vehicle.

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

  62. DISCONNECT REAR ENGINE MOUNTING INSULATOR


    1. A01IQBD

      Remove the bolt to disconnect the rear engine mounting insulator.

  63. REMOVE ENGINE WIRE


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

  64. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. A01IT9L

      Disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    2. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  65. REMOVE STARTER ASSEMBLY


    1. A01IS23

      Open the terminal cap, remove the nut and disconnect the No. 2 engine wire from the starter assembly.

    2. Remove the nut and disconnect the engine wire from the starter assembly.

    3. A01IRF4

      Using an E14 "TORX" socket wrench, remove the 2 bolts and starter assembly.

  66. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01IPNW

      Remove the 4 bolts and front engine mounting bracket.

  67. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01IUI1

      Remove the 5 bolts and rear engine mounting bracket.

  68. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  69. INSTALL ENGINE TO ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.


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

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01IQ7L

      Remove the 2 bolts and front engine mounting insulator from the front crossmember sub-assembly.

  71. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01ISM7

      Remove the 2 bolts, 2 nuts and rear engine mounting insulator from the front suspension crossmember sub-assembly.

  72. REMOVE ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. A01IQHM

      Remove the 4 bolts and engine mounting bracket LH from the manual transaxle assembly.

  73. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01IU0P

      Remove the 4 bolts and engine mounting insulator LH from the body.