ДВИГАТЕЛЬ В СБОРЕ (для моделей с контроллером свечей накаливания) СНЯТИЕ

CAUTION / NOTICE / HINT

CAUTION:

Some of these service operations affect the multi-mode manual transaxle system. Read the precautionary notices concerning the multi-mode manual transaxle system before servicing.

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Note


  • When the manual transaxle assembly or multi-mode manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the manual transaxle assembly or multi-mode manual transaxle assembly allows the compressed clutch release with bearing cylinder assembly to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.

  • After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" using the GTS.

    Click here

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. REMOVE FRONT WHEELS

  5. REMOVE FRONT LOWER BUMPER ABSORBER


    1. Remove the 8 bolts, 4 screws and front lower bumper absorber.

  6. REMOVE NO. 1 ENGINE UNDER COVER (for Half Cover Type)


    1. Remove the 2 bolts, 7 clips and No. 1 engine under cover.

  7. REMOVE NO. 1 ENGINE UNDER COVER (for Full Cover Type)


    1. Remove the 2 bolts, 11 clips and No. 1 engine under cover.

  8. REMOVE CENTER NO. 4 ENGINE UNDER COVER (for Half Cover Type)


    1. Remove the 5 clips and center No. 4 engine under cover.

  9. REMOVE CENTER NO. 4 ENGINE UNDER COVER (for Full Cover Type)


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

  10. REMOVE FRONT NO. 3 ENGINE UNDER COVER (for Full Cover Type)


    1. Remove the 4 clips and front No. 3 engine under cover.

  11. REMOVE REAR ENGINE UNDER COVER LH


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

  12. REMOVE REAR ENGINE UNDER COVER RH


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

  13. DRAIN ENGINE OIL

    Click here

  14. DRAIN ENGINE COOLANT

    Click here

  15. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  16. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)


    1. B0044O9C02
      B0042CO Disengage the 2 grommets first
      B0043VS Disengage the 2 hooks next

      Lift the front of the No. 1 engine cover to disengage the 2 grommets from the 2 pins. Then disengage the 2 hooks from the No. 2 engine cover bracket, and remove the No. 1 engine cover.

  17. REMOVE OUTER COWL TOP PANEL (for LHD)

    Click here

  18. REMOVE OUTER COWL TOP PANEL (for RHD)

    Click here

  19. REMOVE BATTERY


    1. B0042PD

      Loosen the nut, and separate the cable from the positive (+) battery terminal.

    2. Remove the nut, bolt, battery clamp sub-assembly and battery clamp bolt.

    3. Remove the battery.

    4. Remove the battery tray.

  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. B0042HD

      Disconnect the wire harness clamp, connector and ventilation hose.

    2. Loosen the hose clamp.

    3. Unlock the 2 lock clamps and remove the air cleaner cap sub-assembly.

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B0041ON

      Remove the air cleaner filter element sub-assembly.

    2. B0041Y6

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

  22. REMOVE FUEL FILTER ASSEMBLY

    Click here

  23. DISCONNECT ENGINE WIRE


    1. B0043OZ

      Pull up the lever to disengage the ECM connector.

    2. Disengage the 3 wire harness clamps from the fuel filter support.

    3. Remove the No. 1 relay block cover from the engine room relay block and junction block assembly.

    4. B00437Q

      Remove the 2 nuts from the engine room relay block and junction block assembly.

    5. Disengage the 2 claws, and disconnect the 4 wire harness connectors and wire harness from the engine room relay block and junction block assembly.

    6. B0042LI

      Disengage the 2 wire harness clamps.

    7. B0042EN

      Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.

  24. REMOVE GLOW PLUG RELAY ASSEMBLY


    1. B00438L

      Remove the bolt and disconnect the glow plug relay assembly from the fuel filter support.

    2. Disconnect the wire harness clamp from the fuel filter support.

  25. REMOVE FUEL FILTER SUPPORT


    1. B0044N3

      Disconnect the wire harness clamp from the fuel filter support.

    2. Remove the 3 bolts and fuel filter support.

  26. REMOVE AIR CLEANER BRACKET


    1. B00435T

      Remove the 3 bolts and air cleaner bracket.

  27. REMOVE NO. 2 BATTERY CARRIER


    1. B0043FF

      Remove the 4 bolts and No. 2 battery carrier.

  28. REMOVE NO. 3 AIR HOSE


    1. B0044D8

      Loosen the 2 hose clamps and remove the No. 3 air hose.

  29. REMOVE INTERCOOLER AIR HOSE


    1. B0044C7

      Loosen the 2 hose clamps and remove the intercooler air hose.

  30. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


    1. B004528N02

      Remove the 2 clips (A) and disconnect the transmission control cable assembly from the manual transaxle assembly.

    2. Remove the 2 clips (B) and disconnect the transmission control cable assembly from the control cable bracket assembly.

    3. B0044X1

      Remove the bolt and disconnect the transmission control cable assembly from the rear engine mounting bracket.

  31. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. B0042HI

      Slide the clip and disconnect the union to connector tube hose from the cylinder head cover sub-assembly.

  32. DISCONNECT WATER BY-PASS HOSE


    1. B0042OX

      Slide the clip and disconnect the water by-pass hose from the water inlet.

  33. DISCONNECT NO. 2 RADIATOR HOSE


    1. B00441F

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

  34. DISCONNECT NO. 1 RADIATOR HOSE


    1. B0044GF

      Slide the clip and disconnect the No. 1 radiator hose from the outlet water sub-assembly.

  35. DISCONNECT INLET HEATER WATER HOSE A (w/o Combustion Type Power Heater)


    1. B0042PP

      Slide the clip and disconnect the inlet heater water hose A from the inlet heater water pipe A.

  36. DISCONNECT INLET HEATER WATER HOSE D (w/ Combustion Type Power Heater)


    1. B0042PP

      Slide the clip and disconnect the inlet heater water hose D from the inlet heater water pipe A.

  37. DISCONNECT OUTLET HEATER WATER HOSE


    1. B00451U

      Slide the clip and disconnect the outlet heater water hose from the water by-pass pipe sub-assembly.

  38. REMOVE V-RIBBED BELT

    Click here

  39. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)


    1. B00422F

      Disconnect the connector.

    2. B00439U

      Remove the 2 bolts and 2 nuts.

    3. B0041MD

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

    4. Separate the compressor assembly with pulley.

      Tech Tips

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

  40. SECURE STEERING WHEEL

    Click here

  41. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  42. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  43. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  44. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  45. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  46. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  47. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  48. DISCONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)


    1. B0042AI

      Using a 10 mm union nut wrench, disconnect the No. 1 clutch hose from the accumulator to flexible hose tube.

    2. Remove the clip and separate the No. 1 clutch hose from the flexible hose bracket.

  49. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)

    Click here

  50. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  51. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  52. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  53. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  55. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set an engine lifter.

      Note


      • Place the height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

      • Do not place the height adjustment attachments or plate lift attachments under the front crossmember sub-assembly.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

    2. B0042CI

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

    3. B0041TF

      Remove the 4 bolts and front crossmember sub-assembly.

    4. B0043K8

      Remove the 3 nuts and separate the engine mounting insulator sub-assembly RH.

    5. B0043J9

      Remove the through bolt and nut, and separate the engine mounting insulator LH.

      Tech Tips

      When removing the through bolt, keep the nut from rotating.

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

      Note

      Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

  56. INSTALL ENGINE HANGER


    1. B0042N1C01
      *1 No. 1 Engine Hanger
      *2 Bolt
      *a Tab
      *b Hole

      Install the No. 1 engine hanger with a new bolt as shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • Be sure to install the No. 1 engine hanger with the tab contacting the rear side of the hole.

      • Be sure to use a new bolt to install the No. 1 engine hanger.

      Tech Tips

      No. 1 Engine Hanger 12281-33080
      Bolt 91552-81050
    2. B0044H7C01
      *1 No. 2 Engine Hanger
      *2 Bolt

      Install the No. 2 engine hanger with a new bolt as shown in the illustration.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      Note

      Be sure to use a new bolt to install the No. 2 engine hanger.

      Tech Tips

      No. 2 Engine Hanger 12282-0N010
      Bolt

      91672-81025

      90119-W0026

    3. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

  57. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B0044GO

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

      Tech Tips

      When removing the through bolt, keep the nut from rotating.

  58. REMOVE REAR ENGINE MOUNTING INSULATOR


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

      B0042ELC01
      *A Type A *B Type B
  59. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B00420X

      Remove the 4 bolts and engine mounting insulator LH.

  60. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. B00450C

      Remove the 2 bolts and separate the radiator reserve tank assembly.

    2. B0042D0

      Remove the bolt and separate the cooler pipe clamp bracket from the engine mounting insulator sub-assembly RH.

    3. Disconnect the cooler pipe clamp from the engine mounting insulator sub-assembly RH.

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

  61. REMOVE NO. 1 AIR TUBE

    Click here

  62. REMOVE STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  63. REMOVE STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  64. DISCONNECT WIRE HARNESS


    1. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.

  65. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  66. REMOVE BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)

    Click here

  67. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

  69. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE (for Manual Transaxle)

    Click here

  70. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  71. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  72. REMOVE ENGINE WIRE


    1. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.

  73. REMOVE NO. 2 AIR TUBE


    1. B0044AC

      Loosen the hose clamp.

    2. Remove the 2 bolts and No. 2 air tube from the diesel throttle body assembly and cylinder block sub-assembly.

  74. REMOVE NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  75. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  76. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  77. REMOVE NO. 2 ENGINE COVER BRACKET

    Click here

  78. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B0042Y2

      Remove the wiring harness clamp bracket from the cylinder head cover sub-assembly.

  79. REMOVE SENSOR BRACKET

    Click here

  80. REMOVE NO. 1 TURBO INSULATOR

    Click here

  81. REMOVE NO. 2 VACUUM PIPE

    Click here

  82. REMOVE NO. 5 MANIFOLD SUPPORT BRACKET

    Click here

  83. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET

    Click here

  84. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  85. REMOVE NO. 2 EXHAUST MANIFOLD


    1. B0042GE

      Disconnect the camshaft position sensor connector.

    2. Disconnect the exhaust gas temperature sensor connector.

    3. Remove the bolt and wiring harness clamp bracket from the timing chain cover sub-assembly.

    4. Disengage the claw to disconnect the exhaust gas temperature sensor wire connector from the wiring harness clamp bracket.

    5. Disengage the clamp to disconnect the exhaust gas temperature sensor wire from the wiring harness clamp bracket.

    6. Remove the 4 bolts, 3 nuts and No. 2 exhaust manifold from the turbocharger sub-assembly, No. 1 converter support bracket, manifold stay and No. 2 converter support bracket.

      B0041OH
    7. B0041NK

      Remove the outlet turbine elbow gasket from the turbocharger sub-assembly.

  86. REMOVE MANIFOLD SUPPORT BRACKET


    1. B0041LK

      Remove the 3 bolts and manifold support bracket from the cylinder block sub-assembly.

  87. DISCONNECT NO. 1 TURBO WATER HOSE

    Click here

  88. DISCONNECT NO. 2 TURBO WATER HOSE

    Click here

  89. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  90. REMOVE TURBOCHARGER STAY

    Click here

  91. REMOVE MANIFOLD STAY

    Click here

  92. REMOVE TURBOCHARGER SUB-ASSEMBLY

    Click here

  93. REMOVE EXHAUST MANIFOLD

    Click here

  94. REMOVE CYLINDER BLOCK SIDE COVER


    1. B0044AA

      Remove the bolt, plate washer and cylinder block side cover from the cylinder block sub-assembly.

  95. REMOVE CRANK POSITION SENSOR

    Click here

  96. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  97. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  98. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

  99. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly.