ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle assembly 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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

    Click here

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

  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 UNDER COVER

    Click here

  7. DRAIN ENGINE COOLANT

    Click here

  8. REMOVE HEADLIGHT ASSEMBLY

  9. REMOVE FRONT LOWER BUMPER ABSORBER

    Click here

  10. REMOVE NO. 1 ENGINE COVER

    1. A372600N01

      Lift the No. 1 engine cover to detach the 4 clips in the sequence shown in the illustration 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.

  11. REMOVE FRONT FLOOR COVER

    Click here

  12. REMOVE NO. 2 ENGINE UNDER COVER

    1. A332570

      Remove the bolt, clip and No. 2 engine under cover.

  13. REMOVE FRONT FLOOR COVER RH

    1. A297530

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

  14. REMOVE REAR ENGINE UNDER COVER RH

    Click here

  15. REMOVE REAR ENGINE UNDER COVER LH

    1. A299169

      Remove the 2 clips and rear engine under cover LH.

  16. DRAIN ENGINE OIL

    Click here

  17. DRAIN MANUAL TRANSAXLE OIL

    Click here

  18. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  19. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  20. REMOVE BATTERY INSULATOR

  21. REMOVE BATTERY

  22. REMOVE BATTERY TRAY

  23. REMOVE BATTERY CARRIER ASSEMBLY

    Click here

  24. REMOVE BATTERY BRACKET REINFORCEMENT

    Click here

  25. REMOVE RADIATOR ASSEMBLY

    Click here

  26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  27. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  29. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  30. REMOVE RADIATOR RESERVOIR ASSEMBLY

    1. A372605

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

    2. Slide the clamp and disconnect the No. 2 water by-pass hose assembly from the radiator reservoir assembly.

    3. Remove the 2 bolts and radiator reservoir assembly.

  31. REMOVE WATER BY-PASS HOSE ASSEMBLY

    1. A319847

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 1 air tube assembly.

    2. A318482

      Remove the water by-pass hose assembly from the water by-pass pipe.

  32. REMOVE RADIATOR HOSE SUB-ASSEMBLY

    1. A319848

      Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 air tube assembly.

    2. A319849

      Remove the radiator hose sub-assembly from the water outlet.

  33. DISCONNECT VACUUM HOSE

    1. A318485

      Slide the clamp and disconnect the vacuum hose from the No. 2 vacuum hose assembly.

  34. DISCONNECT NO. 2 FUEL HOSE

    1. A372606

      Disconnect the No. 2 fuel hose from the fuel feed pipe sub-assembly.

  35. DISCONNECT FUEL HOSE

    1. Disconnect the fuel hose from the fuel feed pipe sub-assembly.

  36. DISCONNECT WATER HOSE SUB-ASSEMBLY

    1. A354306

      Slide the clamp and disconnect the water hose sub-assembly from the No. 1 air tube assembly.

  37. DISCONNECT OUTLET HEATER WATER HOSE

    1. A354307

      Slide the clamp and disconnect the outlet heater water hose from the No. 1 air tube assembly.

  38. DISCONNECT ENGINE WIRE

    1. Remove the No. 1 engine room relay block cover.

    2. A372603

      Disconnect the 3 connectors.

    3. A372604

      Remove the nut.

    4. Detach the 2 claws to disconnect the engine wire from the No. 1 engine room relay block.

    5. A318483

      Remove the bolt to disconnect the ground cable.

  39. REMOVE FUEL FILTER ASSEMBLY

    Click here

  40. REMOVE GLOW PLUG RELAY ASSEMBLY

    1. Disengage the glow plug relay assembly from the ECM bracket.

  41. REMOVE FUEL FILTER SUPPORT

    1. A372607

      Raise the lever while pushing the lock on the lever, and disconnect the ECM connector.

      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. A372608

      Disconnect the connector.

    3. Detach the 4 clamps to disconnect the engine wire.

    4. Detach the clamp to disconnect the wire harness.

    5. A372609

      Remove the 3 bolts and fuel filter support.

    6. Remove the nut and fuel filter support stay.

  42. REMOVE AIR CLEANER BRACKET

    1. A372610

      Remove the 3 bolts and air cleaner bracket.

  43. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. A372611

      Remove the 2 pins and disconnect the 2 transmission control cable assemblies from the manual transaxle assembly.

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

  44. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  45. SECURE STEERING WHEEL

    Click here

  46. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  47. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  49. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  50. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT

    Click here

  51. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A372613

      Remove the 2 bolts and front suspension member reinforcement LH.

  52. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    1. A372612

      Remove the 2 bolts and front suspension member reinforcement RH.

  53. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  54. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  55. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    1. A372623

      Remove the 2 bolts and front suspension crossmember sub-assembly.

  56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. Set an engine lifter.

      Note:

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

      • Do not position 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. A373932

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

    3. A372616

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A372598

      Detach the 2 clamps and disconnect the air conditioner tube and accessory assembly.

    5. Detach the 2 clamps and disconnect the suction pipe sub-assembly.

    6. A372599

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

    7. A372614

      Remove the bolt and nut to remove the engine mounting insulator LH.

      Tip:

      While holding the bolt in place, loosen the nut.

    8. A372615

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

      Tip:

      When removing the bolt, keep the nut from rotating.

    9. 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.

    10. Using an engine sling device and engine lift, secure the engine assembly with transaxle.

      Note:

      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedures 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.

  57. DISCONNECT REAR ENGINE MOUNTING INSULATOR

    1. A372617

      Remove the bolt to disconnect the rear engine mounting insulator.

  58. REMOVE ENGINE WIRE

    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine assembly, and then remove the bracket bolts and engine wire from the engine assembly.

  59. REMOVE NO. 1 AIR TUBE ASSEMBLY

    1. Disconnect the compressor outlet elbow to the turbocharger sub-assembly.

    2. A339101

      Disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    3. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  60. REMOVE NO. 1 CLUTCH HOUSING COVER

    Click here

  61. REMOVE NO. 2 MANIFOLD STAY

    Click here

  62. REMOVE STARTER ASSEMBLY

    Click here

  63. REMOVE FRONT ENGINE MOUNTING BRACKET

    1. A372618

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

  64. REMOVE REAR ENGINE MOUNTING BRACKET

    1. A318505

      Remove the 5 bolts and rear engine mounting bracket from the manual transaxle assembly.

  65. REMOVE ENGINE MOUNTING BRACKET LH

    1. A372621

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

  66. REMOVE MANUAL TRANSAXLE ASSEMBLY

    1. C341143

      Remove the 6 bolts and manual transaxle assembly from the engine assembly.

  67. 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 assembly while it is suspended, as doing so is dangerous.

    1. Install the engine assembly to an engine stand, and remove the sling device and chain block from the engine assembly.

  68. REMOVE FRONT ENGINE MOUNTING INSULATOR

    1. A372619

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

  69. REMOVE REAR ENGINE MOUNTING INSULATOR

    1. A372620

      Remove the 2 bolts, 2 nuts and rear engine mounting insulator from the front suspension crossmember sub-assembly.

  70. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A372622

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