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 Click here.
Note
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.
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.
After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester.
(w/ DPF: Click here
(w/o DPF: Click here
PROCEDURE
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.
REMOVE REGARDING PARTS REMOVAL (for Multi-Mode Manual Transaxle)
Before removing the clutch actuator or transaxle assembly from the vehicle, perform the Active Test to set the clutch actuator to the "Clamp" position Click here.
Note
If the actuator is not set to the "Clamp" position, the clutch fluid may be sprayed out.
Tech Tips
If the clutch actuator cannot be set to the "Clamp" position due to a malfunction (sticking, etc.), then the clutch fluid pressure should be released from the bleeder plug to prevent the fluid from spraying.
RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE FRONT WHEELS
REMOVE CENTER ENGINE UNDER COVER
REMOVE ENGINE UNDER COVER RH
REMOVE ENGINE UNDER COVER LH
DRAIN ENGINE COOLANT
DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)
DRAIN MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)
REMOVE FRONT WIPER MOTOR AND LINK
REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)
REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)
REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)
REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)
REMOVE INNER COWL TOP TO COWL BRACE (for LHD)
REMOVE INNER COWL TOP TO COWL BRACE (for RHD)
REMOVE OUTER COWL TOP PANEL (for LHD)
REMOVE OUTER COWL TOP PANEL (for RHD)
REMOVE NO. 1 ENGINE COVER
*1 | Pin |
*2 | Hook |
*3 | Bracket |
Raise the front of the No. 1 engine cover to detach the 2 pins. Then remove the 2 No. 1 engine cover hooks from the bracket, and remove the No. 1 engine cover.
REMOVE RADIATOR RESERVE TANK ASSEMBLY
Disconnect the No. 4 water by-pass hose.
*1 | No. 4 Water By-pass Hose |
*2 | Water By-pass Hose Assembly |
Disengage the hose clamp and disconnect the water by-pass hose assembly.
Remove the bolt and reserve tank.
REMOVE RADIATOR RESERVE TANK BRACKET
Remove the bolt and radiator reserve tank bracket.
REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE
Disconnect the mass air flow meter connector.
Disengage the 4 wire harness clamps and separate the wire harness from the air cleaner cap.
Unlock the 2 lock clamps and separate the air cleaner cap.
Disconnect the fuel hose from the hose clamp.
Disconnect the ventilation hose from the cylinder head cover.
Disconnect the air cleaner hose from the turbocharger and remove the air cleaner cap with hose.
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
REMOVE AIR CLEANER BRACKET
Disengage the wire harness clamp.
Remove the 3 bolts and the air cleaner bracket.
REMOVE BATTERY
Disconnect the cable from the positive (+) battery terminal.
Loosen the 2 nuts and remove the battery clamp.
Remove the battery.
REMOVE BATTERY TRAY
Remove the battery tray.
REMOVE BATTERY CARRIER (for LHD)
Disengage the 3 wire harness clamps and disconnect the wire harness from the battery carrier.
Remove the 5 bolts and battery carrier.
REMOVE BATTERY CARRIER (for RHD)
Disengage the 4 wire harness clamps and disconnect the wire harness from the battery carrier.
Remove the 5 bolts and battery carrier.
REMOVE FAN AND GENERATOR V BELT
DISCONNECT SUCTION HOSE (w/ Air Conditioning System)
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)
REMOVE COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)
DISCONNECT UNION TO CONNECTOR TUBE HOSE
Disconnect the union to connector tube hose.
DISCONNECT NO. 2 FUEL HOSE SUB-ASSEMBLY
Disconnect the No. 2 fuel hose sub-assembly.
DISCONNECT OUTLET HEATER WATER HOSE
Disconnect the outlet heater water hose.
DISCONNECT INLET HEATER WATER HOSE
Disconnect the inlet heater water hose.
REMOVE NO. 2 AIR HOSE
Remove the No. 2 air hose.
REMOVE NO. 1 RADIATOR HOSE
Remove the No. 1 radiator hose.
DISCONNECT NO. 2 RADIATOR HOSE
Disconnect the No. 2 radiator hose.
REMOVE NO. 3 AIR HOSE
Remove the No. 3 air hose.
REMOVE NO. 1 AIR TUBE
Remove the bolt and separate the wire harness.
Loosen the hose clamp.
Remove the 2 nuts and No. 1 air tube.
SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
SEPARATE CLUTCH HOSE
REMOVE ENGINE WIRE
Disconnect the 3 connectors from the positive (+) battery terminal.
Disengage wire harness clamp and disconnect the current sensor connector and glow relay connector.
Disengage the wire harness clamp and disconnect the ECM connector and wire harness clamp.
Remove the engine junction block cover.
Remove the bolt and separate the ground wire.
Disengage the wire harness clamp.
Disconnect the 2 connectors from the engine junction block.
Disengage the 2 claws and separate the wire harness from the junction block.
Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.
DISCONNECT TRANSAXLE WIRE (for Multi-Mode Manual Transaxle)
Disconnect the 5 connectors and 2 clamps.
REMOVE COLUMN HOLE COVER SILENCER SHEET
SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY
SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
REMOVE FRONT FLOOR CENTER BRACE
REMOVE FRONT EXHAUST PIPE ASSEMBLY
REMOVE FRONT DRIVE SHAFT ASSEMBLY
REMOVE OIL PAN COVER
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
Place wooden blocks or plate lift attachments in the positions as shown in the illustration and set an engine lifter underneath the crossmember.
Attachment Placement Positions |
Note
Place the wooden blocks or plate lift attachments so that the front suspension crossmember sub-assembly is level.
As the engine assembly with transaxle is very heavy, be sure to support it securely.
To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.
Remove the 2 bolts and engine mounting stay.
Remove the bolt and 3 nuts and separate the engine mounting insulator RH.
Remove the through bolt and nut and separate the engine mounting insulator LH.
Remove the 6 bolts, the engine assembly with transaxle and the front suspension crossmember from the vehicle.
INSTALL ENGINE HANGER (w/ DPF)
*1 | No. 1 Engine Hanger |
*2 | Bolt |
*3 | Tab |
*a | Engine Rear |
Install the No. 1 engine hanger with a new bolt as shown in the illustration.
Part Name | Part No. |
---|---|
No. 1 Engine Hanger | 12281-33050 |
Bolt | 91552-81050 |
Note
Be sure to install the engine hanger with the tab contacting the rear side of the hole.
Be sure to use new bolts to install the engine hanger.
*1 | No. 2 Engine Hanger |
*2 | Bolt |
Install the No. 2 engine hanger with a new bolt as shown in the illustration.
Part Name | Part No. |
---|---|
No. 2 Engine Hanger | 12282-33050 |
Bolt | 91672-81025 |
Note
Be sure to use a new bolt to install the engine hanger.
Using an engine sling device and a chain block, suspend the engine assembly with transaxle.
INSTALL ENGINE HANGER (w/o DPF)
*1 | No. 1 Engine Hanger |
*2 | Bolt |
*3 | Tab |
*a | Engine Rear |
Install the No. 1 engine hanger with a new bolt as shown in the illustration.
Part Name | Part No. |
---|---|
No. 1 Engine Hanger | 12281-33050 |
Bolt | 91552-81050 |
Note
Be sure to install the engine hanger with the tab contacting the rear side of the hole.
Be sure to use new bolts to install the engine hanger.
*1 | No. 2 Engine Hanger |
*2 | Bolt |
Install the No. 2 engine hanger with a new bolt as shown in the illustration.
Part Name | Part No. |
---|---|
No. 2 Engine Hanger | 12282-33022 |
Bolt | 91672-81025 |
Note
Be sure to use a new bolt to install the engine hanger.
Using an engine sling device and a chain block, suspend the engine assembly with transaxle.
REMOVE WATER BY-PASS HOSE ASSEMBLY
Remove the water by-pass hose assembly.
REMOVE NO. 2 RADIATOR HOSE
Remove the No. 2 radiator hose.
REMOVE NO. 2 AIR TUBE ASSEMBLY
Loosen the hose clamp.
Remove the bolt and No. 2 air tube assembly.
REMOVE STARTER ASSEMBLY (except Cold Area)
REMOVE STARTER ASSEMBLY (for Cold Area Specification Vehicles)
FIX TRANSAXLE
Using an engine sling device and a chain block, hold the engine assembly.
To enable removal of the engine assembly, adjust the positions of the plate lift attachments and set them in place.
Note
Set the plate lift attachments so that the engine assembly with transaxle is level.
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.
To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.
Use a belt with a tighten mechanism or a rope to secure the engine assembly with transaxle to the engine lifter.
Note
Do not tighten the belt with a tightening mechanism or the rope any more than is necessary.
Set the engine assembly with transaxle so that it is horizontal.
REMOVE ENGINE ASSEMBLY
Remove the 8 bolts and engine assembly from the manual transaxle.
REMOVE BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)
REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)
REMOVE CLUTCH TUBE BOOT (for Manual Transaxle)
REMOVE CLUTCH TUBE BOOT (for Multi-Mode Manual Transaxle)
REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)
REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)
REMOVE BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)
REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
REMOVE CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)
REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)
REMOVE CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)
REMOVE NO. 2 VACUUM PIPE (w/ DPF)
REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (w/ DPF)
REMOVE NO. 4 MANIFOLD SUPPORT BRACKET (w/ DPF)
REMOVE NO. 3 MANIFOLD SUPPORT BRACKET (w/ DPF)
REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)
REMOVE NO. 2 ENGINE COVER BRACKET
REMOVE DIFFERENTIAL PRESSURE SENSOR (w/ DPF)
Remove the differential pressure sensor connector.
Disconnect the 2 vacuum transmitting hoses.
Remove the nut and differential pressure sensor.
REMOVE NO. 1 TURBO INSULATOR (w/ DPF)
REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)
REMOVE MANIFOLD SUPPORT BRACKET (w/ DPF)
Remove the 3 bolts and manifold support bracket.
REMOVE NO. 2 MANIFOLD SUPPORT BRACKET (w/ DPF)
Remove the 2 bolts and No. 2 manifold support bracket.
REMOVE NO. 1 TURBO INSULATOR (w/o DPF)
REMOVE MANIFOLD SUPPORT BRACKET (w/o DPF)
REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)
REMOVE TURBOCHARGER STAY
REMOVE MANIFOLD STAY
SEPARATE TURBO OIL INLET PIPE SUB-ASSEMBLY
REMOVE TURBOCHARGER SUB-ASSEMBLY
REMOVE EXHAUST MANIFOLD
REMOVE CYLINDER BLOCK SIDE COVER
Remove the bolt, washer plate and the cylinder block side cover.
REMOVE CRANKSHAFT POSITION SENSOR (w/ DPF)
Disconnect the crankshaft position sensor connector.
Disengage the crankshaft position sensor connector wire harness clamp from the wire harness bracket.
Remove the 2 bolts and crankshaft position sensor.
REMOVE CRANKSHAFT POSITION SENSOR (w/o DPF)
REMOVE FLYWHEEL SUB-ASSEMBLY
Using SST, hold the crankshaft.
Remove the 6 bolts and flywheel.
REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Remove the No. 1 crankshaft position sensor plate.
DISCONNECT ENGINE WIRE
*a | Engine side |
*b | Transaxle side |
Disconnect the 2 ground bolts.
Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.
REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tech Tips
Only perform this procedure when replacement of the engine mounting insulator RH is necessary.
Remove the 3 bolts and engine mounting insulator RH.
REMOVE ENGINE MOUNTING INSULATOR LH
Tech Tips
Only perform this procedure when replacement of the engine mounting insulator LH is necessary.
Remove the 5 bolts and engine mounting insulator LH.