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 assembly and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder assembly to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.

PROCEDURE

  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. REMOVE NO. 2 CYLINDER HEAD COVER

    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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  7. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  8. REMOVE REAR ENGINE UNDER COVER RH

    1. A297336

      Remove the 3 clips and rear engine under cover RH.

  9. REMOVE REAR ENGINE UNDER COVER LH

    A296295

    1. Remove the 3 clips and rear engine under cover LH.

  10. DRAIN ENGINE COOLANT

    Click here

  11. DRAIN ENGINE OIL

    Click here

  12. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

  13. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

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

    Click here

  15. REMOVE RADIATOR RESERVOIR ASSEMBLY

    1. A292528

      Slide the 2 clamps and disconnect the No. 1 and No. 2 water by-pass hoses from the radiator reservoir assembly.

    2. Remove the 2 bolts and radiator reservoir assembly.

  16. REMOVE V-RIBBED BELT

    Click here

  17. REMOVE GENERATOR ASSEMBLY

    Click here

  18. DISCONNECT NO. 2 RADIATOR HOSE

    1. A292532

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

  19. DISCONNECT COMPRESSOR WITH PULLEY ASSEMBLY

    1. A292529

      Disconnect the connector.

    2. A292530

      Remove the 2 bolts and 2 nuts.

    3. A292531

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the compressor with pulley assembly.

      Tip:

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  22. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  23. REMOVE BATTERY

  24. REMOVE BATTERY TRAY

  25. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  26. REMOVE FRONT BATTERY BRACKET

    Click here

  27. REMOVE BATTERY BRACKET REINFORCEMENT

    Click here

  28. REMOVE ECM

    Click here

  29. DISCONNECT NO. 1 RADIATOR HOSE

    1. A300873

      for CVT:

      Disconnect the breather plug hose from the clamp.

    2. A292533

      Slide the clamp and disconnect the No. 1 radiator hose from the cylinder head.

  30. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    1. A298964

      Remove the No. 1 fuel pipe clamp, and then disconnect the fuel tube sub-assembly.

      Click here

  31. DISCONNECT WIRE HARNESS AND HOSE

    1. A292534

      Detach the 2 clamps and remove the bolt.

    2. A292536

      Disconnect the 2 connectors and remove the nut.

    3. A292537

      Detach the 2 claws and slide the wire harness, and then disconnect the wire harness.

    4. A270920

      Disconnect the terminal cap, and then remove the nut and disconnect the starter wire.

    5. Detach the wire harness clamp.

    6. A292539

      for Manual Transaxle:

      Detach the clamp, remove the bolt and disconnect the engine wire from the manual transaxle.

    7. A270921

      for CVT:

      Detach the clamp, remove the bolt and disconnect the engine wire from the CVT.

    8. A292538

      Slide the clamp and disconnect the connector tube hose from the air tube.

    9. A209171

      Slide the 2 clamps and disconnect the heater water outlet hose and heater water inlet hose from the heater core.

  32. DISCONNECT TRANSAXLE CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    1. C277986

      Remove the 2 clips and disconnect the top ends of the transaxle control cable assembly from the transaxle.

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

  33. DISCONNECT TRANSAXLE CONTROL CABLE ASSEMBLY (for CVT)

    1. C203394

      Remove the nut and disconnect the transaxle control cable assembly from the control shaft lever.

    2. Remove the clip and disconnect the transaxle control cable assembly from the control cable bracket.

    3. C201443

      Disconnect the transaxle control cable assembly from the control cable support.

    4. C131876

      Remove the bolt and disconnect the clamp of the control cable.

  34. 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.

  35. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  36. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  38. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  39. REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

  40. DISCONNECT FRONT SPEED SENSOR LH

    Click here

  41. DISCONNECT FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  42. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  44. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  45. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

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

    Click here

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

    Tip:

    Use the same procedure described for the LH side.

  48. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

  49. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING

  50. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

  51. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  52. DISCONNECT HEATED OXYGEN SENSOR (for 4WD/AWD)

    Click here

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

    Click here

  54. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)

  55. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT (for 2WD)

    1. A295897

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

  56. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A296303

      Remove the 4 bolts and front suspension member reinforcement LH.

  57. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    1. A296302

      Remove the 4 bolts and front suspension member reinforcement RH.

  58. INSTALL ENGINE HANGER

    1. A292543

      Detach the fuel tube clamp.

    2. Disconnect the air fuel ratio sensor connector and remove the bolt and air fuel ratio sensor bracket.

    3. A150573C04

      *1

      No. 1 Engine Hanger

      *2

      No. 2 Engine Hanger

      Install the 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

      12281-37021

      No. 2 Engine Hanger

      12282-37011

      Bolt

      91552-81050

  59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. A296304

      Remove the 6 bolts and front crossmember sub-assembly.

    2. A292540C01

      *A

      for Manual Transaxle

      *B

      for CVT

      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. A292541

      Remove the bolt and 2 nuts, and disconnect the engine mounting insulator RH.

    5. A292542C01

      *A

      for Manual Transaxle

      *B

      for CVT

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

    6. A296308

      Remove the 6 bolts and front suspension member brace rear RH and 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. A298936

      Remove the through bolt and front suspension crossmember 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.

  60. REMOVE STEERING GEAR HEAT INSULATOR (for RHD)

    Click here

  61. REMOVE STARTER ASSEMBLY

  62. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

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

    Click here

  64. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

  65. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

  66. 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 transaxle as doing so may deform the oil pan.

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

  67. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

    Click here

  68. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  69. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  70. REMOVE CLUTCH TUBE (for Manual Transaxle)

    Click here

  71. REMOVE CLUTCH RELEASE BLEEDER SUB-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 ENGINE WIRE

    1. Remove the engine wire from the engine.

  75. 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.

  76. REMOVE DRIVE SHAFT BEARING BRACKET

    A298937

    1. Remove the 3 bolts and drive shaft bearing bracket.

  77. REMOVE REAR ENGINE MOUNTING INSULATOR

    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.

      A293519C01

      *A

      for 2WD

      *B

      for 4WD / AWD

      *C

      for Manual Transaxle

      *D

      for CVT

  78. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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

    1. A293520

      Remove the bolt and radiator reservoir bracket.

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

  79. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A293521

      Remove the bolt and wire harness clamp bracket.

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