ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

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.

PROCEDURE

  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  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 NO. 1 ENGINE COVER

    A203808

    1. Detach the 4 clips and remove the No. 1 engine cover.

      Note:

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

  7. REMOVE NO. 1 ENGINE UNDER COVER

    A272192

    1. Remove the 4 bolts and 2 screws.

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

  8. REMOVE FRONT FLOOR COVER

    Click here

  9. REMOVE FRONT FLOOR COVER RH

    1. A297530

      Loosen the 3 nuts and remove the 3 clips and front floor cover RH.

  10. REMOVE REAR ENGINE UNDER COVER RH

    Click here

  11. REMOVE REAR ENGINE UNDER COVER LH

    1. A299169

      Remove the 2 clips and rear engine under cover LH.

  12. DRAIN ENGINE COOLANT

    Click here

  13. DRAIN ENGINE OIL

    Click here

  14. DRAIN MANUAL TRANSAXLE OIL

    Click here

  15. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  16. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  17. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    A294113

    1. Remove the bolt and loosen the nut.

    2. Detach the 2 wire harness clamps.

    3. Detach the hook of the battery clamp sub-assembly from the front battery bracket, and then remove the battery clamp sub-assembly.

  18. REMOVE BATTERY INSULATOR

  19. REMOVE BATTERY

  20. REMOVE BATTERY TRAY

  21. REMOVE FRONT BATTERY BRACKET

    A294114

    1. Detach the 2 wire harness clamps.

    2. Remove the 4 bolts and front battery bracket.

  22. REMOVE BATTERY BRACKET REINFORCEMENT

    A294115

    1. Remove the 2 bolts and battery bracket reinforcement.

  23. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  24. REMOVE NO. 3 AIR HOSE

    Click here

  25. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    1. Disconnect the PCV hose.

    2. Loosen the hose clamp and disconnect the air cleaner hose.

    3. A294116

      Disconnect the mass air flow meter connector and wire harness clamp.

    4. Detach the 3 clips and remove the air cleaner cap sub-assembly.

  26. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  27. REMOVE AIR CLEANER CASE

    1. A294117

      Remove the 3 bolts and air cleaner case.

  28. REMOVE AIR CLEANER SUPPORT

    1. A294118

      Remove the 2 nuts and air cleaner support.

  29. REMOVE FUEL FILTER ASSEMBLY

    1. A294121

      Slide the clip and disconnect the 2 fuel hoses.

    2. Remove the bolt and fuel filter assembly.

  30. REMOVE AIR CLEANER BRACKET

    1. A294119

      Disconnect the glow relay and level warning switch connector.

    2. A294120

      Detach the 3 wire harness clamps.

    3. A294122

      Disconnect the 2 fuel hoses from the air cleaner bracket.

    4. Remove the 3 bolts and air cleaner bracket.

  31. REMOVE ECM

    Click here

  32. DISCONNECT HOSES AND CONNECTORS

    1. Remove the engine room relay block and junction block cover.

    2. A294123

      Disconnect the 3 connectors from the engine room No. 1 relay block.

    3. A294124

      Remove the nut.

    4. Detach the 2 claws and disconnect the engine wire.

    5. A294125

      Disconnect the 2 connectors from the No. 8 engine wire.

    6. A294126

      Remove the bolt and disconnect the engine wire cover clamp and engine wire harness clamp.

    7. Remove the nut and disconnect the starter wire.

    8. A272271

      Remove the bolt from the wire harness bracket.

    9. A294129

      Detach the clamp, remove the bolt and disconnect the ground cable from the manual transaxle assembly.

    10. A294130

      Detach the wire harness clamp and disconnect the 2 connectors.

    11. A295883

      Remove the bolt from the manual transaxle assembly.

    12. A294128

      Detach the 3 wire harness clamps from the 3 wire harness brackets.

    13. A295884

      Detach the 2 wire harness clamps and disconnect the 4 injector driver connectors.

    14. A295885

      Remove the 2 nuts and injector driver assembly.

    15. A295888

      Slide the clip and disconnect the vacuum pump hose from the vacuum pump assembly.

  33. DISCONNECT INLET HEATER WATER HOSE

    1. A208836

      Slide the clamp and disconnect the inlet heater water hose from the cylinder head sub-assembly.

  34. DISCONNECT OUTLET HEATER WATER HOSE

    1. Slide the clamp and disconnect the outlet heater water hose from the No. 3 water by-pass pipe.

  35. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    A295889

    1. Slide the clamp and disconnect the radiator hose sub-assembly from the cylinder head sub-assembly.

  36. REMOVE INTERCOOLER AIR HOSE

    Click here

  37. DISCONNECT NO. 2 WATER BY-PASS HOSE

    1. A295891

      Slide the clamp and disconnect the No. 2 water by-pass hose from the No. 4 water by-pass pipe.

  38. DISCONNECT NO. 2 RADIATOR HOSE

    1. A295890

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

  39. REMOVE RADIATOR RESERVOIR ASSEMBLY

    A295892

    1. Slide the clamp and disconnect the water by-pass hose from the radiator reservoir assembly.

    2. Remove the 2 bolts and radiator reservoir assembly.

  40. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    1. A297510

      Remove the bolt and disconnect the discharge hose sub-assembly.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

    3. Disconnect the cooler compressor connector.

  41. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    1. Remove the bolt and disconnect the suction hose sub-assembly.

    2. Remove the O-ring from the suction hose sub-assembly.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  42. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. A295893

      Remove the 2 pins.

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

  43. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    1. A297525

      Remove the 4 bolts and disconnect the clutch release cylinder assembly and clutch flexible hose bracket.

  44. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  45. SECURE STEERING WHEEL

  46. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  48. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  49. REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Perform the same procedure as for the LH side.

  50. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  51. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  52. REMOVE FRONT AXLE ASSEMBLY LH

    Click here

  53. REMOVE FRONT AXLE ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  56. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT

    1. A295897

      Remove the 2 bolts and front lower engine mounting bracket reinforcement.

  57. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A295896

      Remove the 4 bolts and front suspension member reinforcement LH.

  58. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  59. REMOVE FUEL HOSE PROTECTOR

    1. A210097

      Remove the fuel hose protector from the cylinder head sub-assembly.

  60. INSTALL ENGINE HANGER

    1. A297520C01

      *1

      No. 1 Engine Hanger

      *2

      No. 2 Engine Hanger

      Install the 2 engine hangers with the 2 bolts as shown in the illustration.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

      Tip:
      Table 1. 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 sub-assembly.

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

  61. REMOVE ENGINE WITH TRANSAXLE

    1. A295898

      Remove the 6 bolts and disconnect the front crossmember sub-assembly.

    2. A295899

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

    3. Set an engine lifter underneath the engine.

      Tip:

      Place the engine on wooden blocks or equivalent so that the engine is level.

    4. A295901

      Remove the 2 bolts and 2 nuts and disconnect the engine mounting insulator sub-assembly RH.

    5. A295902

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

    6. A273397

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

    7. Remove the 2 bolts and front suspension member sub-assembly.

    8. Carefully remove the engine with transaxle 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.

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

    10. A295903

      Remove the bolt and disconnect the rear engine mounting insulator.

  62. REMOVE NO. 1 AIR TUBE

    1. A272272

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

  63. REMOVE STARTER ASSEMBLY

    Click here

  64. REMOVE ENGINE WIRE

    Click here

  65. REMOVE FRONT ENGINE MOUNTING BRACKET

    1. A295907

      Remove the 3 bolts and front engine mounting bracket.

  66. REMOVE REAR ENGINE MOUNTING BRACKET

    1. A272266

      Remove the 5 bolts and rear engine mounting bracket.

  67. REMOVE ENGINE MOUNTING BRACKET LH

    Tip:

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

    1. A272273

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

  68. REMOVE OIL PAN INSULATOR

    1. A202319

      Remove the 2 bolts and oil pan insulator.

  69. REMOVE STIFFENER PLATE RH

    1. A202320

      Remove the 4 bolts and stiffener plate RH.

  70. REMOVE STIFFENER PLATE LH

    1. A202321

      Remove the 4 bolts and stiffener plate LH.

  71. FIX ENGINE ASSEMBLY

    1. Using wooden blocks or plate lift attachments, set the engine on a flat surface.

      Note:

      • Place wooden blocks or plate lift attachments so that the engine is level.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

      • Perform this step while supporting the engine assembly using a sling device and chain block.

  72. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Click here

  73. REMOVE CLUTCH COVER ASSEMBLY

    Click here

  74. REMOVE CLUTCH DISC ASSEMBLY

    Click here

  75. REMOVE FLYWHEEL WITH DAMPER ASSEMBLY

    1. A297509N01

      Using SST, hold the crankshaft pulley.

      09213-58014

      91551-80840

      09330-00021

    2. A202344

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

  76. INSTALL ENGINE TO ENGINE STAND

    Note:

    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    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 engine hanger and No. 2 engine hanger.

  77. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A295905

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

  78. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A272274

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

  79. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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

    1. A300904

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