ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle 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.

PROCEDURE

  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click hereClick here

  3. 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.

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  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

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  5. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  6. REMOVE NO. 1 ENGINE COVER

    A203808

    1. Detach the 4 clips 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.

  7. REMOVE NO. 1 ENGINE UNDER COVER

    A295999

    1. Remove the 4 bolts and 2 screws.

    2. Remove the 10 clips and No. 1 engine under cover.

  8. REMOVE FRONT FLOOR COVER

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  9. REMOVE NO. 2 ENGINE UNDER COVER

    1. A332570

      Remove the bolt, clip and No. 2 engine under cover.

  10. REMOVE FRONT FLOOR COVER RH

    1. A297530

      Loosen the 3 nuts and remove the 3 clips and front floor cover RH.

  11. REMOVE REAR ENGINE UNDER COVER RH

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  12. REMOVE REAR ENGINE UNDER COVER LH

    A299169

    1. Remove the 2 clips and rear engine under cover LH.

  13. DRAIN ENGINE COOLANT

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  14. DRAIN ENGINE OIL

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  15. DRAIN AUTOMATIC TRANSAXLE FLUID

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  16. DRAIN TRANSFER OIL

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  17. REMOVE FRONT BUMPER COVER

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  18. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  19. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  20. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

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  21. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    A294113

    1. Remove the bolt and loosen the nut.

    2. Detach the 2 wire harness clamps.

    3. Detach the hook of the battery clamp sub-assembly from the front battery bracket, and then remove the battery clamp sub-assembly.

  22. REMOVE BATTERY INSULATOR

  23. REMOVE BATTERY

  24. REMOVE BATTERY TRAY

  25. REMOVE FRONT BATTERY BRACKET

    A294114

    1. Detach the 2 wire harness clamps.

    2. Remove the 4 bolts and front battery bracket.

  26. REMOVE BATTERY BRACKET REINFORCEMENT

    A294115

    1. Remove the 2 bolts and battery bracket reinforcement.

  27. REMOVE RADIATOR ASSEMBLY

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  28. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

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  29. REMOVE NO. 3 AIR HOSE

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  30. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    1. Disconnect the PCV hose.

    2. Loosen the hose clamp and disconnect the air cleaner hose.

    3. A294116

      Disconnect the mass air flow meter connector and wire harness clamp.

    4. Detach the 3 clips and remove the air cleaner cap sub-assembly.

  31. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  32. REMOVE AIR CLEANER CASE

    1. A294117

      Remove the 3 bolts and air cleaner case.

  33. REMOVE AIR CLEANER SUPPORT

    1. A294118

      Remove the 2 nuts and air cleaner support.

  34. REMOVE FUEL FILTER ASSEMBLY

    1. A294121

      Slide the clip and disconnect the 2 fuel hoses.

    2. Remove the bolt and fuel filter assembly.

  35. REMOVE AIR CLEANER BRACKET

    1. A294119

      Disconnect the glow plug relay and level warning switch connector.

    2. A294120

      Detach the 3 wire harness clamps.

    3. A294122

      Disconnect the 2 fuel hoses from the air cleaner bracket.

    4. Remove the 3 bolts and air cleaner bracket.

  36. REMOVE ECM

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  37. DISCONNECT HOSES AND CONNECTORS

    1. Remove the engine room relay block and junction block cover.

    2. A294123

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

    3. A294124

      Remove the nut.

    4. Detach the 2 claws and disconnect the engine wire.

    5. A294126

      Remove the bolt and disconnect the engine wire cover clamp and engine wire harness clamp.

    6. Remove the nut and disconnect the starter wire.

    7. A297513

      Remove the bolt from the wire harness clamp bracket.

    8. A297511

      Disconnect the transaxle ECM connector and detach the 2 wire harness clamps.

    9. Remove the bolt and disconnect the ground cable from the automatic transaxle.

    10. A297512

      Detach the 2 clamps and disconnect the transaxle shift position switch connector.

    11. A294128

      Detach the 3 wire harness clamps from the 3 wire harness brackets.

    12. A295884

      Detach the 2 wire harness clamps and disconnect the 4 injector driver connectors.

    13. A295885

      Remove the 2 nuts and injector driver assembly.

    14. A295887

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

  38. DISCONNECT INLET HEATER WATER HOSE

    1. A208836

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

  39. DISCONNECT OUTLET HEATER WATER HOSE

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

  40. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    A295889

    1. Slide the clamp and disconnect the radiator hose sub-assembly from the cylinder head sub-assembly.

  41. REMOVE INTERCOOLER AIR HOSE

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  42. DISCONNECT NO. 2 WATER BY-PASS HOSE

    1. A295891

      Slide the clamp and disconnect the No. 2 water by-pass hose from the No. 4 water by-pass pipe.

  43. DISCONNECT NO. 2 RADIATOR HOSE

    1. A295890

      Slide the clamp and disconnect the No. 2 radiator hose from the water inlet housing.

  44. REMOVE RADIATOR RESERVOIR ASSEMBLY

    A295892

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

    2. Remove the 2 bolts and radiator reservoir assembly.

  45. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    1. A297510

      Remove the bolt and disconnect the discharge hose sub-assembly.

    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.

    3. Disconnect the cooler compressor connector.

  46. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    1. Remove the bolt and disconnect the suction hose sub-assembly.

    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.

  47. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. A208877

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

  48. REMOVE COLUMN HOLE COVER SILENCER SHEET

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  49. SECURE STEERING WHEEL

  50. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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

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  52. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  53. REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Perform the same procedure as for the LH side.

  54. DISCONNECT FRONT SPEED SENSOR LH

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  55. DISCONNECT FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  56. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click hereClick here

  57. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  58. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click hereClick here

  59. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  60. REMOVE FRONT AXLE ASSEMBLY LH

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  61. REMOVE FRONT AXLE ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click hereClick here

  63. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click hereClick here

  64. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A295896

      Remove the 4 bolts and front suspension member reinforcement LH.

  65. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

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  66. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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  67. REMOVE FUEL HOSE PROTECTOR

    1. A210097

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

  68. INSTALL ENGINE HANGER

    1. A297520C01

      *1

      No. 1 Engine Hanger

      *2

      No. 2 Engine Hanger

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

      40 N*m

      408 kgf*cm

      30 ft.*lbf

      Tip:
      Table 1. Part No.

      No. 1 Engine Hanger

      12281-26040

      No. 2 Engine Hanger

      12282-26010

      Bolt

      91552-81025 or 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.

  69. REMOVE ENGINE WITH TRANSAXLE

    1. A295898

      Remove the 6 bolts and disconnect the front crossmember sub-assembly.

    2. A295899

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

    3. Set an engine lifter underneath the engine.

      Tip:

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

    4. A295901

      Remove the 2 bolts and 2 nuts and disconnect the engine mounting insulator sub-assembly RH.

    5. A295902

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

    6. A273397

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

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

    8. Carefully remove the engine with transaxle 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.

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

    10. A295903

      Remove the through bolt and disconnect the rear engine mounting insulator.

  70. REMOVE NO. 1 AIR TUBE

    A273393

    1. Loosen the hose clamp, and remove the 2 bolts and No. 1 air tube.

  71. REMOVE STARTER ASSEMBLY

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  72. REMOVE ENGINE WIRE

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  73. REMOVE FRONT ENGINE MOUNTING BRACKET

    1. A212913

      Remove the 4 bolts and front engine mounting bracket.

  74. REMOVE REAR ENGINE MOUNTING BRACKET

    1. A224434

      Remove the 4 bolts and rear engine mounting bracket.

  75. REMOVE ENGINE MOUNTING BRACKET LH

    Tip:

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

    1. A299459

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

  76. REMOVE OIL PAN INSULATOR

    1. A202319

      Remove the 2 bolts and oil pan insulator.

  77. REMOVE STIFFENER PLATE RH

    1. A202320

      Remove the 4 bolts and stiffener plate RH.

  78. REMOVE STIFFENER PLATE LH

    1. A202321

      Remove the 4 bolts and stiffener plate LH.

  79. FIX ENGINE ASSEMBLY

    1. Using wooden blocks or plate lift attachments, set the engine on a flat surface.

      Note:

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

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

      • Perform this step while supporting the engine assembly using a sling device and chain block.

  80. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

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  81. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    1. A208894

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

  82. 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 while it is suspended, as doing so is dangerous.

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

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

  83. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A295905

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

  84. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A299460

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

  85. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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

    1. A300904

      Remove the 3 bolts and engine mounting insulator sub-assembly RH from the body.