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.

Note:

for Manual Transaxle:

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.

PROCEDURE

  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

  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 hereClick here

  5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  6. REMOVE NO. 1 ENGINE UNDER COVER

    1. A302699C01

      *A

      for Half Cover Type

      *B

      for Full Cover Type

      for Half Cover Type:

      Remove the 6 screws, 5 clips and No. 1 engine under cover.

    2. for Full Cover Type:

      Remove the 2 screws, 4 bolts, 8 clips and No. 1 engine under cover.

  7. REMOVE REAR ENGINE UNDER COVER RH

    1. A297336

      Remove the 3 clips and rear engine under cover RH.

  8. REMOVE REAR ENGINE UNDER COVER LH

    1. A302695C01

      *A

      for Half Cover Type

      *B

      for Full Cover Type

      for Half Cover Type:

      Remove the 3 clips and rear engine under cover LH.

    2. for Full Cover Type:

      Remove the 2 clips and rear engine under cover LH.

  9. REMOVE FRONT FLOOR COVER (w/ Canister Pump Module)

    Click here

  10. DRAIN ENGINE COOLANT

    Click here

  11. DRAIN ENGINE OIL

    Click here

  12. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

  13. DRAIN TRANSFER OIL (for 4WD/AWD)

    Click here

  14. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

  15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  16. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  17. REMOVE BATTERY INSULATOR

    Click here

  18. REMOVE BATTERY

    Click here

  19. REMOVE BATTERY TRAY

    Click here

  20. REMOVE FRONT BATTERY BRACKET

    Click here

  21. REMOVE BATTERY BRACKET REINFORCEMENT

    Click here

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE AIR CLEANER CASE

    Click here

  24. REMOVE ECM

    Click here

  25. DISCONNECT RADIATOR RESERVOIR ASSEMBLY

    Click here

  26. REMOVE FAN AND GENERATOR V BELT

    Click here

  27. REMOVE GENERATOR ASSEMBLY

    Click here

  28. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  29. REMOVE RADIATOR HOSE HOSE CLAMP

    Click here

  30. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  31. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  32. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  33. REMOVE TRANSMISSION OIL COOLER (for Automatic Transaxle)

  34. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    1. A240912

      Remove the No. 1 fuel pipe clamp.

    2. Disconnect the fuel tube connector.

      Click here

  35. DISCONNECT WIRE HARNESS AND HOSE

    1. A296296

      Remove the terminal cap.

    2. A296297

      Remove the nut, and disconnect the clamp and starter wire harness.

    3. A296300

      Remove the bolt. Then disconnect the 2 clamps and wire harness.

    4. A296298

      Remove the nut from the engine room No. 1 relay block.

    5. Disconnect the 2 connectors, detach the 2 claws from the engine room No. 1 relay block and disconnect the wire harness.

    6. A296299

      Remove the bolt and disconnect the wire harness.

    7. A296301

      Slide the clip and disconnect the vacuum hose from the No. 1 hose to hose tube.

    8. A297338

      for Manual Transaxle:

      1. Detach the heater hose from the clamp.

      2. Slide the clip and disconnect the heater hose from the cylinder head sub-assembly.

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

    9. A297337

      for Automatic Transaxle:

      1. Slide the clip and disconnect the heater hose from the cylinder head sub-assembly.

      2. Slide the clip and disconnect the heater hose from the No. 1 water by-pass pipe.

  36. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    1. A296888

      Remove the 4 clips and disconnect the 2 transmission control cables.

  37. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

    1. A296889

      Remove the nut and disconnect the transmission control cable from the control shaft lever.

    2. Remove the clip and disconnect the transmission control cable from the control cable bracket.

  38. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  39. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  40. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  41. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  42. REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

  43. DISCONNECT FRONT SPEED SENSOR LH

    Click here

  44. DISCONNECT FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  45. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  46. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  47. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  48. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  49. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  50. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  51. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

  52. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

  53. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

  54. REMOVE DRIVE SHAFT BEARING BRACKET

    1. Remove the 3 bolts and bracket.

  55. REMOVE FLYWHEEL HOUSING UNDER COVER

    1. A196625

      Remove the flywheel housing under cover.

  56. DISCONNECT CLUTCH HOSE (for Manual Transaxle)

    1. A296890

      Using a 10 mm union nut wrench, disconnect the clutch hose from the accumulator to flexible hose tube.

    2. Remove the clip and disconnect the clutch hose.

  57. REMOVE FRONT NO. 2 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  58. REMOVE FRONT EXHAUST PIPE SUB-ASSEMBLY

    Click here

  59. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transaxle)

  60. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD/AWD)

    Click here

  61. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A296303

      Remove the 4 bolts and front suspension member reinforcement LH.

  62. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    1. A296302

      Remove the 4 bolts and front suspension member reinforcement RH.

  63. INSTALL ENGINE HANGER

    1. A195856C06

      *1

      No. 1 Engine Hanger

      *2

      No. 2 Engine Hanger

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

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Tip:

      No. 1 Engine Hanger

      12281-36020

      No. 2 Engine Hanger

      12282-36021

      Bolt

      91552-81025

      91552-81040

  64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. A296304

      Remove the 6 bolts and front crossmember sub-assembly.

    2. A296305

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

      Note:

      While holding the nut in place, loosen the through bolt.

    3. Set an engine lifter underneath the engine.

      Note:

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

    4. A296306

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

    5. A296307

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

    6. A296308

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

    7. A296309

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

    8. Operate the engine lifter and slowly remove the engine 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. A296310

      Remove the through bolt and front suspension crossmember sub-assembly from the engine with transaxle.

      Note:

      Do not damage any engine or transaxle components.

      Tip:

      Raise the engine with transaxle assembly while keeping it level.

  65. REMOVE STARTER ASSEMBLY

    Click here

  66. REMOVE TRANSFER ASSEMBLY (for 4WD/AWD)

    Click here

  67. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

  68. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

  69. 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.

  70. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  71. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

  73. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  74. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)

    Click here

  75. REMOVE ENGINE WIRE

    1. Remove the engine wire from the engine.

  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 with the bolts.

    2. Remove the 2 bolts and 2 engine hangers.

  77. REMOVE REAR ENGINE MOUNTING INSULATOR

    A296311
    Tip:

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

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

  78. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A296312
    Tip:

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

    1. Remove the bolt and radiator reservoir bracket.

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

  79. REMOVE ENGINE MOUNTING SPACER

    A296313
    Tip:

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

    1. Remove the 2 bolts and engine mounting spacer.

  80. REMOVE ENGINE MOUNTING INSULATOR LH

    A296314
    Tip:

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

    1. Remove the bolt and wire harness clamp bracket.

    2. Remove the 4 bolts and engine mounting insulator LH.