ENGINE ASSEMBLY REMOVAL

Note

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. INSPECT DRIVE AWAY RELEASE FUNCTION (for Manual Transaxle)

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge fuel system pressure Click here.

  3. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A010LI3

      Hold the rear of the cover and raise it to detach the 2 clips on the rear of the cover. Continue to raise the cover to detach the 2 clips on the front of the cover and remove the cover.

      Note

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

  4. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A00OKW2

      Remove the 7 clips and 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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  8. REMOVE FRONT WHEEL

  9. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A00OL3A

      Remove the 4 screws and 2 bolt.

    2. A00OI9A

      Remove the 3 screws, 8 bolts and front lower bumper absorber.

  10. REMOVE NO. 1 ENGINE UNDER COVER


    1. A00ON3U

      Remove the 10 clips and under cover.

  11. REMOVE REAR ENGINE UNDER COVER RH


    1. A00OMDF

      Remove the 5 clips and under cover RH.

  12. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and under cover.

  13. REMOVE CENTER NO. 4 ENGINE UNDER COVER


    1. A00ONX6

      Remove the 2 clips and under cover.

  14. REMOVE NO. 2 ENGINE UNDER COVER


    1. A00OLHN

      Remove the 4 clips and under cover.

  15. 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 reserve tank cap.

      CAUTION:

      Do not remove the reserve tank cap while the engine and radiator are still hot.

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

      A00DSEWE01
      Text in Illustration
      *1 Reserve Tank Cap *2 Radiator Drain Cock Plug
  16. 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.

  17. DRAIN MANUAL TRANSAXLE OIL


    1. A010KSSE02
      Text in Illustration
      *1 Filler Plug

      Remove the filler plug and gasket.

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

      Text in Illustration
      *2 Drain Plug
    3. Install a new gasket and the drain plug.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
  18. DISCONNECT RADIATOR RESERVOIR ASSEMBLY


    1. A00OII3

      Remove the 2 bolts and disconnect the radiator reservoir.

    2. Remove the grommet from the radiator reservoir.

  19. REMOVE V-RIBBED BELT


    1. A00OILIE01

      Loosen bolts A and B.

    2. Loosen bolt C and remove the V-ribbed belt.

      Note

      Do not loosen bolt D.

  20. REMOVE GENERATOR ASSEMBLY


    1. A00ONWT

      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. A00OK6FE01

      Remove the 2 bolts and adjusting bar.

    5. A00OKGNE01

      Remove the bolt and generator.

    6. A00OJ9U

      Remove the bolt and wire harness clamp bracket.

  21. DISCONNECT NO. 2 RADIATOR HOSE


    1. A00ON88

      Disconnect the radiator hose from the water inlet.

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


    1. A00OJFT

      Disconnect the connector.

    2. Remove the 2 bolts and 2 nuts.

    3. A00OO0Y

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

      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.

  23. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A010LIZ

      Disconnect the mass air flow meter connector.

    2. Detach the wire harness from the 2 clamps.

    3. A010LJ4

      Disconnect the 2 clamps.

    4. A010IQW

      Disconnect the ventilation hose.

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

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A010IG6

      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. A00OLE3E01

      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. A00OHVH

      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. A00OKIS

      Remove the 4 bolts and battery carrier.

  29. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A00OL2L

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

    2. A00OHWH

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

    3. A00OIVA

      Remove the nut and disconnect the control cable.

  30. DISCONNECT CLUTCH HOSE


    1. A00OKSL

      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.

  31. DISCONNECT NO. 1 RADIATOR HOSE


    1. A00OLL1

      Disconnect the radiator hose from the cylinder head.

  32. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A00ONLJ

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

    2. A00OI2V

      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 plastic bags after disconnecting the fuel tube.

      • If the fuel tube connector and pipe are stuck, push and pull to release them.

  33. DISCONNECT HEATER WATER HOSE


    1. A00ONW9

      Disconnect the 2 heater water hoses.

  34. DISCONNECT WIRE HARNESS AND HOSE


    1. A00OMUSE01

      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. A00OIXH

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

    3. Disconnect the 3 connectors, detach the 2 clamps from the engine room No. 1 relay block and disconnect the wire harness.

    4. A00OIJZ

      Disconnect the connector from the battery current sensor.

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

    6. A00ONVV

      Remove the bolt and disconnect the engine wire.

    7. A00OLLT

      Disconnect the connector tube hose.

    8. A00OMQX

      Disconnect the vacuum hose.

  35. SECURE STEERING WHEEL ASSEMBLY


    1. A010KCN

      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.

  36. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A00OJTQ

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

  37. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A00OMQT

      Remove the bolt.

      Note

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

    2. A00ONO5E01
      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.

  38. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY


    1. Remove the No. 1 steering column hole cover from the steering link.

  39. REMOVE FRONT CENTER FLOOR BRACE


    1. A00DQAY

      Remove the 4 bolts and floor brace.

  40. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A00DRN8

      Remove the 2 bolts and 2 compression springs.

    2. Remove the 2 exhaust pipe supports and front exhaust pipe assembly.

  41. REMOVE FRONT AXLE SHAFT NUT LH


    1. A010KIAE01

      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.

  42. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedures described for the LH side.

  43. 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.

  44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedures described for the LH side.

  45. REMOVE FRONT AXLE ASSEMBLY LH


    1. Remove the front axle assembly LH Click here.

  46. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedures described for the LH side.

  47. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A00DQNKE01

      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.

  48. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  49. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A00OI0E

      Remove the 4 bolts and front suspension member reinforcement LH.

  50. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A00OJKI

      Remove the 4 bolts and front suspension member reinforcement RH.

  51. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A00OK43

      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. A00OJ5H

      Remove the 4 bolts and front crossmember.

  52. 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. A00ONME

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

    3. A00OL79

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

    4. A00OJJV

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

    5. A00ON82

      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.

  53. INSTALL ENGINE HANGER


    1. A00OLB6

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

    2. A00OMWEE01
      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.

  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A00OL49

      Remove the bolt and front suspension crossmember from the engine.

  55. REMOVE STARTER ASSEMBLY


    1. Disconnect the terminal cap.

    2. A00OLFME01

      Remove the nut and disconnect the starter wire.

    3. Disconnect the connector.

    4. Remove the 2 bolts and starter.

  56. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. A00OJTH

      Remove the flywheel housing side cover from the cylinder block.

  57. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. Remove the manual transaxle assembly Click here.

  58. REMOVE CLUTCH COVER ASSEMBLY

    A005SPCE02
    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.

  59. REMOVE CLUTCH DISC ASSEMBLY

  60. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A00DPL0E01

      Using SST, hold the crankshaft.

      SST
      09330-00021
      09213-58014   ( 91551-80840 )
    2. A00DQFN

      Remove the 8 bolts and flywheel.

  61. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


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

  62. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  63. 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.

  64. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A00OHRD

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

  65. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A00OJRL

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

  66. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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

    A00OHT2

    1. Disconnect the cooler pipe clamp.

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

    3. A00OMAM

      Remove the 3 bolts and engine mounting insulator.

  67. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

    Tech Tips

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

    A00OHZI

    1. Remove the 4 bolts and engine mounting insulator.