ENGINE ASSEMBLY REMOVAL


  1. INSPECT BASIC FUNCTION

    Click here

  2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  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 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. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  6. REMOVE FRONT WHEEL

  7. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  8. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY


    1. A003D5G

      Detach the wire harness clamp and disconnect the sensor connector.

    2. Remove the bolt and sensor.

    3. Disconnect the 2 vacuum hoses.

  9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A00ORFK

      Disconnect the connector and detach the harness clamp.

    2. A00OTJV

      Remove the 9 bolts and outer cowl top panel.

  10. REMOVE NO. 1 ENGINE COVER


    1. A00ORGX

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

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

  11. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A00OVQR

      Remove the 7 clips and radiator support opening cover.

  12. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A00OVPY

      Remove the 4 screws and 2 bolts.

    2. A00OUR6

      Remove the 8 bolts and 3 screws.

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

  13. REMOVE NO. 1 ENGINE UNDER COVER


    1. A00ORDS

      Remove the 11 clips the engine under cover.

  14. REMOVE CENTER NO. 4 ENGINE UNDER COVER


    1. A00OV0V

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

  15. REMOVE NO. 2 ENGINE UNDER COVER


    1. A00E945

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

  16. REMOVE REAR ENGINE UNDER COVER RH


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

  17. REMOVE REAR ENGINE UNDER COVER LH


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

  18. 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.

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      Tech Tips

      The plug is on the backside of the generator on the EGR cooler side.

      A00OSDBE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Cylinder Block Drain Cock Plug (Type A) *4 Cylinder Block Drain Cock Plug (Type B)
      *4 Radiator Drain Cock Plug - -
  19. 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 }
  20. DRAIN MANUAL TRANSAXLE OIL

    A003E2JE01
    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 }
  21. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  22. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A00OQGF

      Remove the bolt and loosen the nut.

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

  23. REMOVE BATTERY

  24. REMOVE BATTERY TRAY

  25. REMOVE BATTERY CARRIER


    1. A00OU72

      Detach the 2 clamps and disconnect the wire harness.

    2. Remove the 4 bolts and battery carrier.

  26. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A00OVD1

      Disconnect the No. 2 vacuum transmitting hose from the intake manifold.

  27. REMOVE NO. 3 AIR HOSE


    1. A00OW4Z

      Loosen the 2 hose clamps.

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

  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A00OT02

      Disconnect the mass air flow meter connector.

    2. Disconnect the No. 2 ventilation hose.

    3. Disconnect the air cleaner hose.

    4. Detach the 4 clamps and remove the air cleaner cap.

  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  30. REMOVE AIR CLEANER CASE


    1. A00OUZE

      Remove the 3 bolts and air cleaner case.

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


    1. A00E6Q8E01

      Disconnect the 4 fuel hoses.

    2. A00E7QY

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

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


    1. A00E84F

      Disconnect the 5 fuel hoses.

    2. A00E7QY

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  33. DISCONNECT HOSES AND CONNECTORS


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

    2. Disconnect the current sensor connector.

    3. A00OR04

      Disconnect the 3 connectors.

    4. Remove the 2 nuts.

    5. Detach the 2 claws and remove the engine room No. 1 relay block.

    6. A00OS5E

      Remove the bolt and disconnect the ground cable.

    7. A00OV0LE02
      Text in Illustration
      *A for LHD
      *B for RHD

      for LHD:

      Detach the 5 clamps and disconnect the 2 connectors.

    8. for RHD:

      Detach the 3 clamps and disconnect the 2 connectors.

    9. Remove the 5 bolts and air cleaner bracket.

    10. A00OTGX

      Detach the 4 clamps and disconnect the wire harness.

    11. A00OR7C

      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.

    12. Disconnect the 2 fuel hoses.

    13. A00OQEQ

      Disconnect the vacuum pump hose.

  34. DISCONNECT INLET HEATER WATER HOSE


    1. A00OUYA

      Disconnect the inlet heater water hose.

  35. DISCONNECT OUTLET HEATER WATER HOSE


    1. Disconnect the outlet heater water hose.

  36. DISCONNECT NO. 1 RADIATOR HOSE


    1. A00OT5Q

      Disconnect the No. 1 radiator hose.

  37. REMOVE INTERCOOLER AIR HOSE


    1. A00OV1QE01
      Text in Illustration
      *1 Retainer

      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.

  38. DISCONNECT WATER BY-PASS HOSE


    1. A00OREF

      Disconnect the water by-pass hose.

  39. DISCONNECT NO. 2 RADIATOR HOSE


    1. A00OVSZ

      Disconnect the No. 2 radiator hose.

  40. REMOVE INJECTOR DRIVER


    1. A00ORHG

      Detach the clamp and disconnect the 4 connectors.

    2. A00OV7Z

      Remove the 3 screws and injector driver.

  41. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A00OVDV

      Remove the 4 bolts and front suspension member reinforcement.

  42. REMOVE FAN AND GENERATOR V BELT


    1. Using SST and a 22 mm wrench, rotate the tensioner pulley counterclockwise to loosen the belt tension. Then remove the belt.

      A00OTC1E01
      SST
      09216-42010

      CAUTION:


      • Be careful as the wrench only fits loosely on the belt tensioner tool set point. The wrench may come off the set point and cause injuries.

      • Be careful that your hands do not become jammed between parts such as the belt, pulleys, etc.

      Note

      Make sure SST is installed as shown in the illustration. If not, SST and/or the belt may not be able to be removed.

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


    1. A00OV77

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. A00OW3J

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

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A00OQVL

      Remove the 2 pins.

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

  45. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A00OSNA

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

  46. SECURE STEERING WHEEL


    1. A010RQT

      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.

  47. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A00OTXT

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

  48. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A00ORI7

      Remove the bolt.

      Note

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

    2. A00OW2XE01
      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.

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

    A010NOXE02

    1. 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.

      Text in Illustration
      *1 Lip
      *2 Clip B
      *3 Clip A
      *4 Lip
  50. REMOVE FRONT AXLE SHAFT NUT LH


    1. A010RJ1E01

      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.

  51. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  52. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH


    1. A003AFXE03

      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.

  53. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  54. REMOVE FRONT AXLE ASSEMBLY LH


    1. Remove the front axle assembly LH Click here.

  55. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  56. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A00E9TYE01

      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.

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A00E8PO

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

    2. Remove the drive shaft from the transaxle.

      Note


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

      • Be careful not to drop the drive shaft.

  58. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A00OR86

      Remove the 4 bolts and front suspension member reinforcement LH.

  59. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A00OW1A

      Remove the 6 bolts and front crossmember.

  60. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A00OR6PE01
      Text in Illustration
      *1 Through Bolt
      *2 Nut

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

  61. REMOVE ENGINE WITH TRANSAXLE


    1. A00OTCM

      Remove the bolt and disconnect the cable bracket.

    2. A00OUW3

      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. A00OR52

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

    5. A00OUV8

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

    6. A00OU34

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

    7. Remove the 2 bolts and suspension crossmember.

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

    9. A00OSAXE01
      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 91552-81025 or 90105-W0042

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

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

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

  62. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A00OU9U

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

  63. REMOVE NO. 1 AIR TUBE


    1. A00OVM9

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

  64. REMOVE STARTER ASSEMBLY (for VALEO Made)


    1. A00OVAG

      Disconnect the starter connector.

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

    3. Remove the 2 bolts and starter.

  65. REMOVE STARTER ASSEMBLY (for DENSO Made)


    1. A00OV06

      Disconnect the starter connector.

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

    3. A00OTTA

      Remove the 2 bolts and starter.

  66. REMOVE ENGINE WIRE

  67. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. Remove the 3 bolts and front engine mounting bracket.

  68. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A00OQMY

      Remove the 5 bolts and rear engine mounting bracket.

  69. REMOVE ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. A00OTEE

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

  70. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A00OTIE

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

  71. REMOVE ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. A00OUOG

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

  72. REMOVE OIL PAN INSULATOR


    1. A00OT5N

      Remove the 2 bolts and oil pan insulator.

  73. REMOVE STIFFENER PLATE RH


    1. A00OUPU

      Remove the 4 bolts and stiffener plate RH.

  74. REMOVE STIFFENER PLATE LH


    1. A00OTBZ

      Remove the 4 bolts and stiffener plate LH.

  75. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  76. REMOVE CLUTCH COVER ASSEMBLY


    1. A00OUQ3E01
      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.

  77. 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.

  78. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A00OQDQE01

      Hold the crankshaft pulley with SST.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A00OSGT

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

  79. 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, No. 1 and No. 2 engine hangers.