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.

Note:

for Manual Transaxle:

When the manual transaxle is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the manual 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. 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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click hereClick here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  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

  7. REMOVE FRONT LOWER BUMPER ABSORBER

    1. Remove the 4 screws, 8 bolts and front lower bumper absorber.

  8. REMOVE NO. 1 ENGINE UNDER COVER (for Half Cover Type)

    1. Remove the 7 clips, 2 screws and No. 1 engine under cover.

  9. REMOVE NO. 1 ENGINE UNDER COVER (for Metal Type)

    1. Remove the 2 clips, 5 bolts and No. 1 engine under cover.

  10. REMOVE NO. 2 ENGINE UNDER COVER

    1. Remove the 5 clips and No. 2 engine under cover.

  11. REMOVE REAR ENGINE UNDER COVER LH

    1. Remove the 5 clips and rear engine under cover LH.

  12. REMOVE REAR ENGINE UNDER COVER RH

    1. Remove the 5 clips and rear engine under cover RH.

  13. DRAIN ENGINE COOLANT

    Click here

  14. DRAIN ENGINE OIL

    Click here

  15. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click hereClick here

  16. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  17. REMOVE NO. 2 CYLINDER HEAD COVER

    1. A307202C01
      V100136

      Disengage the 2 rear side clips first
      V100135

      Disengage the 2 front side clips next

      Lift the rear of the No. 2 cylinder head cover to disengage the 2 rear clips. Lift the front of the No. 2 cylinder head cover to disengage the 2 front clips and remove the cylinder head cover sub-assembly.

      Note:

      Attempting to disengage both front and rear clips at the same time may cause the No. 2 cylinder head cover to break.

  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

    2. A289012

      Disconnect the engine wire harness clamp from the air cleaner case sub-assembly.

    3. Remove the 3 bolts and air cleaner case sub-assembly.

  20. REMOVE BATTERY

    A287979

    1. Loosen the nut, and disconnect the cable from the positive (+) battery terminal.

    2. Remove the bolt and loosen the nut.

    3. Remove the battery clamp sub-assembly and battery.

    4. Remove the battery tray from the battery carrier assembly.

  21. REMOVE BATTERY CARRIER ASSEMBLY

    1. A154156

      Separate the 2 wire harness clamps from the battery carrier assembly.

    2. A154250

      Remove the 2 bolts.

    3. Separate the radiator pipe from the battery carrier assembly.

    4. A200723

      Remove the 4 bolts and battery carrier assembly.

  22. DISCONNECT NO. 1 RADIATOR HOSE (for CVT)

    1. A285508

      Disconnect the breather plug hose from the clamp.

    2. A154266

      Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  23. DISCONNECT NO. 1 RADIATOR HOSE (for Manual Transaxle)

    1. A154266

      Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  24. DISCONNECT NO. 2 RADIATOR HOSE

    1. A154267

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

  25. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

    1. C225426

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

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

    3. C275984

      Remove the bolt and disconnect the transmission control cable assembly from the rear engine mounting insulator.

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

    1. A297327N01

      Remove the 2 clips (A) and disconnect the 2 transmission control cable assemblies from the manual transaxle assembly.

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

    3. C270660

      Remove the bolt and disconnect the transmission control cable assembly from the rear engine mounting bracket.

  27. DISCONNECT CLUTCH HOSE (for Manual Transaxle)

    1. A196105

      Using a 10 mm union nut wrench, disconnect the bleeder clutch release tube from the clutch hose.

    2. Remove the clip and disconnect the clutch hose.

  28. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

    1. A234727

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the duty vacuum switching valve assembly.

  29. DISCONNECT UNION TO VACUUM TUBE HOSE

    1. A296805

      Slide the clip and disconnect the union to vacuum tube hose from the air tube.

  30. DISCONNECT OUTLET HEATER WATER HOSE (for CVT)

    1. A235883

      Slide the clip and disconnect the outlet heater water hose from the air conditioner unit assembly.

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

  31. DISCONNECT HEATER WATER HOSE OUTLET B (for Manual Transaxle)

    1. A235951

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

  32. DISCONNECT INLET HEATER WATER HOSE

    1. A154252

      Slide the clip and disconnect the inlet heater water hose from the air conditioner unit assembly.

  33. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    1. A203501

      Release the claw and remove the No. 1 fuel pipe clamp.

    2. A107343

      Pinch the retainer as shown in the illustration, then pull the fuel tube connector off of the fuel pipe.

      Note:

      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the fuel pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube sub-assembly.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  34. REMOVE V-RIBBED BELT

    Click here

  35. REMOVE GENERATOR ASSEMBLY (for 90A Type)

    Click here

  36. REMOVE GENERATOR ASSEMBLY (for 100A Type)

    Click here

  37. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  38. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  39. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  40. DISCONNECT WIRE HARNESS

    1. A285510

      Pull up the lever and disconnect the ECM connector.

    2. Disconnect the wire harness clamp.

    3. Remove the No. 1 engine room relay block cover from the engine room relay block and junction block assembly.

    4. A285512

      Remove the 2 nuts from the engine room relay block and junction block assembly.

    5. Disconnect the 3 connectors, 2 claws and wire harness from the engine room relay block and junction block assembly.

    6. for CVT:

      1. A289328

        Remove the bolt and disconnect the clamp and No. 3 engine wire from the CVT.

    7. for Manual Transaxle:

      1. A289820

        Remove the bolt and disconnect the No. 3 engine wire from the manual transaxle assembly.

    8. Disconnect all the wire harnesses and connectors.

      Tip:

      Make sure that no wire harness is connected between the body and engine assembly.

  41. SECURE STEERING WHEEL

    Click here

  42. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  43. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  45. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  46. REMOVE DRIVE SHAFT ASSEMBLY

    Click here

  47. REMOVE FLYWHEEL HOUSING UNDER COVER

    1. C118502

      Remove the flywheel housing under cover.

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

    Click hereClick here

  49. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT

    Click hereClick here

  50. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click hereClick here

  51. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tip:

    Perform the same procedure as for the LH side.

  52. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click hereClick here

  53. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click hereClick here

  55. 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 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. A295541

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

    3. A295542

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A150570

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

    5. A289015C05

      *A

      for CVT

      *B

      for Manual Transaxle

      Remove the through bolt and nut, and separate the engine mounting insulator LH.

      Tip:

      When removing the through bolt, keep the nut from rotating.

    6. 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.

  56. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A289017

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

      Tip:

      When removing the through bolt, keep the nut from rotating.

  57. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A296637C02

      *A

      for CVT

      *B

      for Manual Transaxle

      Remove the through bolt and separate the rear engine mounting insulator.

  58. REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. A289018C05

      *A

      for CVT

      *B

      for Manual Transaxle

      Remove the 4 bolts and engine mounting insulator LH.

  59. 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. A287994

      Remove the 2 bolts and radiator reservoir tank.

    2. A289812

      Remove the bolt and cooler pipe clamp bracket from the engine mounting insulator sub-assembly RH.

    3. Disconnect the cooler pipe clamp from the engine mounting insulator sub-assembly RH.

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

  60. REMOVE WIRE HARNESS CLAMP BRACKET

    A235924

    1. Disconnect the clamp and wire harness.

    2. Remove the bolt and wire harness clamp bracket.

  61. INSTALL ENGINE HANGER

    1. A177451C01

      *1

      No. 1 Engine Hanger (Part No.12281-37021)

      *2

      No. 2 Engine Hanger (Part No.12282-37011)

      *3

      Bolt (Part No.91552-81050)

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

    2. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.

  62. DISCONNECT NO. 5 WATER BY-PASS HOSE (for CVT)

    1. A154917

      Slide the clip and disconnect the No. 5 water by-pass hose from the No. 1 water by-pass pipe.

  63. REMOVE ENGINE WIRE

    1. Remove the engine wire from the engine assembly with transaxle.

  64. REMOVE FLYWHEEL HOUSING SIDE COVER

    1. A104497C04

      *a

      Protruding Portion

      *b

      Claw

      Remove the flywheel housing side cover from the stiffening crankcase assembly.

  65. REMOVE STARTER ASSEMBLY

    Click here

  66. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  67. REMOVE BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

    Click here

  68. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

  70. REMOVE CLUTCH RELEASE CYLINDER TO BLEEDER TUBE (for Manual Transaxle)

    Click here

  71. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  72. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

  74. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click hereClick here

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

    Click here

  76. 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.

  77. REMOVE ENGINE HANGER

    1. Remove the 2 bolts and No. 1 engine hanger and No. 2 engine hanger.