ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

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 hereClick here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. SECURE STEERING WHEEL

    Click here

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

    Click hereClick here

  6. REMOVE FRONT WHEELS

    Click here

  7. DRAIN ENGINE OIL

    Click here

  8. DRAIN ENGINE COOLANT

    Click here

  9. DRAIN MANUAL TRANSAXLE OIL

    Click here

  10. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  11. REMOVE FRONT NO. 1 VENTILATOR SEAL

    for LHD:Click here

    for RHD:Click here

  12. REMOVE FRONT AIR SHUTTER SEAL RH

    for LHD:Click here

    for RHD:Click here

  13. REMOVE OUTER COWL TOP PANEL

    for LHD:Click here

    for RHD:Click here

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  15. REMOVE BATTERY

    1. A322536

      Remove the nut and engine room main wire with engine wire from the positive (+) battery terminal.

    2. Disengage the 2 claws to disconnect the engine room main wire from the engine wire.

    3. A322357

      Remove the bolt and No.2 battery clamp from the battery clamp sub-assembly.

    4. Remove the battery from the battery clamp sub-assembly.

  16. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    1. A322358

      Disengage the 5 wire harness clamps and disconnect the wire harness from the battery clamp sub-assembly.

    2. Remove the 5 bolts.

    3. Disengage the claw and remove the battery clamp sub-assembly from the No. 1 engine room relay block.

  17. REMOVE FAN AND GENERATOR V BELT

    Click here

  18. REMOVE GENERATOR ASSEMBLY

    Click here

  19. SEPARATE WITH MAGNET CLUTCH COMPRESSOR (w/ Air Conditioning System)

    1. A327668

      Disconnect the connector.

    2. Remove the 3 bolts and separate the compressor assembly with pulley.

      Tip:

      Secure the compressor and hoses off to the side instead of discharging the A/C system.

  20. DISCONNECT OUTLET HEATER WATER HOSE

    Click here

  21. DISCONNECT INLET HEATER WATER HOSE

    Click here

  22. DISCONNECT NO. 1 RADIATOR HOSE

    Click here

  23. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    1. C302792C01

      *a

      Grommet

      Remove the bolt.

    2. Disengage the guide and grommet to remove the radiator reserve tank assembly as shown in the illustration.

    3. A327468

      Disconnect the water by-pass hose from the radiator reserve tank assembly.

    4. Disconnect the No. 5 water by-pass hose from the radiator reserve tank assembly.

    5. A327667

      Disconnect and remove the No. 5 water by-pass hose from No. 1 water by-pass pipe.

  24. DISCONNECT ENGINE WIRE

    1. A327465

      Raise the lever while pushing the locks on the lever, and disconnect the ECM connectors.

      Note:

      After disconnecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the ECM connector.

    2. A322375

      Remove the No. 1 engine room relay block cover.

    3. A327669

      Disconnect the 2 connectors from the No. 1 engine room relay block.

    4. Remove the nut.

    5. A322369

      Disengage the 2 claws and disconnect wire harness from the No. 1 engine room relay block.

    6. A322370

      Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.

    7. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the vehicle body and engine assembly with transaxle.

  25. REMOVE INTAKE MANIFOLD

    Click here

  26. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  27. DISCONNECT CLUTCH RELEASE CABLE ASSEMBLY

    Click here

  28. REMOVE STEERING COLUMN HOLE COVER PLATE

    Click here

  29. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  31. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  33. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. A330328C01
      V100155

      Attachment Installation Position

      Set an engine lifter.

      Note:

      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

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

    2. A327659

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

    3. A327670

      Remove the 3 bolts, and separate the engine mounting insulator LH.

    4. A322515

      Remove the 6 bolts, engine assembly with transaxle and front suspension crossmember sub-assembly from the vehicle body.

    5. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle body.

      Note:

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

      • While lowering the engine assembly with transaxle from the vehicle body, do not allow it to contact the vehicle body.

  34. INSTALL ENGINE HANGER

    1. A330551C01

      *1

      No. 2 Engine Hanger

      *a

      Claw

      *b

      Groove

      Align the claw of the No. 2 engine hanger with the groove of the cylinder head sub-assembly and install the No. 2 engine hanger with the bolt.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

      Note:

      When installing the No. 2 engine hanger, make sure the No. 2 engine hanger is securely installed to the cylinder head sub-assembly with the bolt.

      Tip:

      No. 2 engine hanger

      12282-36061

      Bolt

      90105-WX013

  35. SECURE ENGINE ASSEMBLY WITH TRANSAXLE

    1. Using an engine sling device and a chain block, hold the engine assembly with transaxle as shown in the illustration.

      A330552

    2. To enable removal of the engine assembly with transaxle, adjust the positions of the height adjustment attachments and plate lift attachments and set them in place.

      Note:

      • Set the height adjustment attachments and plate lift attachments so that the engine assembly with transaxle is horizontal.

      • 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.

    3. A330553

      Using a belt with a ratchet mechanism or a rope, secure the engine assembly with transaxle to the engine lifter.

      Note:

      • Do not tighten the belt with a ratchet mechanism or the rope any more than necessary.

      • Set the engine assembly with transaxle horizontally.

  36. REMOVE ENGINE WIRE

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

  37. REMOVE STARTER ASSEMBLY

    Click here

  38. REMOVE ENGINE ASSEMBLY

    1. A327237C01
      V100135

      Bolt
      V100136

      Nut

      Remove the 5 bolts and 2 nuts.

    2. A330554

      Remove the engine assembly from the manual transaxle.

  39. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  40. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  41. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A327660
    Tip:

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

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

  42. REMOVE ENGINE MOUNTING INSULATOR LH

    A327671
    Tip:

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

    1. Remove the 3 bolts and engine mounting insulator LH from the vehicle body.

  43. INSTALL ENGINE 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.

  44. REMOVE ENGINE HANGER

    1. Remove the bolt, No. 2 engine hanger.