ENGINE ASSEMBLY > REMOVAL

for Preparation Click here


NOTICE:
  1. 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 from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.
  2. After replacing the engine assembly, perform the both "injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester.



1. DISCHARGE FUEL SYSTEM PRESSURE
(Click here)


2. DRAIN ENGINE COOLANT (w/ Water Inlet Drain Cock Plug)



A198899E01


Text in Illustration 
*1
Water Filler Cap Sub-assembly
*3
Radiator Drain Cock Plug
*2
Water Inlet Drain Cock Plug
-
-

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

  1. Loosen the radiator drain cock plug.

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Remove the water filler cap sub-assembly.



    A201664E01

  1. Connect the hose to the water inlet drain cock plug.
    Text in Illustration 
    *1
    		Hose
    *2
    		Water Inlet Clip

  1. Remove the water inlet clip.



    A201666

  1. Pull out the water inlet drain cock plug.



3. DRAIN ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)


A236548E01

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

  1. Loosen the radiator drain cock plug.
    Text in Illustration 
    *1
    		Water Filler Cap Sub-assembly
    *2
    		Radiator Drain Cock Plug

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Remove the water filler cap sub-assembly.



4. DRAIN CVT FLUID (for CVT)


    C195107

  1. Using a socket hexagon wrench (6 mm), remove the drain plug and gasket and drain the fluid.



    C196794E01

  1. Using a socket hexagon wrench (6 mm), remove the No. 1 transmission oil filler tube and drain the fluid.
    Text in Illustration 
    *1
    		No. 1 Transmission Oil Filler Tube



    C196794E01

  1. Using a socket hexagon wrench (6 mm), install the No. 1 transmission oil filler tube.
    Text in Illustration 
    *1
    		No. 1 Transmission Oil Filler Tube

    Torque:
    0.8 N*m{ 8.2 kgf*cm , 7 in.*lbf }



    C195107

  1. Install a gasket and temporarily tighten the drain plug with a socket hexagon wrench (6 mm).

    HINT:
    Because the drain plug will be removed again, the gasket can be reused at this time.



5. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)


C195438E01
Text in Illustration 
*1
Filler plug
*2
Drain plug

  1. Stop the vehicle in a level place.

  1. Remove the manual transmission filler plug and the gasket.

  1. Remove the manual transmission drain plug and gasket, and then drain the manual transaxle oil.



6. REMOVE FRONT WHEELS


7. REMOVE WINDSHIELD WIPER MOTOR AND LINK

  1. Remove the windshield wiper motor and link (Click here).



8. REMOVE FRONT FLOOR COVER LH


9. REMOVE FRONT FLOOR COVER RH


10. REMOVE NO. 2 ENGINE UNDER COVER


11. REMOVE ENGINE UNDER COVER RH


12. REMOVE NO. 3 ENGINE UNDER COVER


A191832

  1. Remove the 3 clips and the No. 3 engine under cover.



13. REMOVE NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)


A240173

  1. Remove the 2 nuts and the No. 1 cooler cover.



14. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)


A240172

  1. Remove the 2 bolts, nut and the No. 1 engine cover.



15. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    A199496

  1. Disconnect the oxygen sensor connector and disengage the clamp.



    A199499

  1. Remove the 2 bolts and the 2 compression springs, and disconnect the front exhaust pipe assembly from the tail exhaust pipe assembly.



    A202951

  1. Remove the 2 bolts and the 2 compression springs, and the front exhaust pipe assembly from the exhaust manifold.



16. REMOVE FAN AND GENERATOR V BELT


A191886E01

  1. Loosen the bolt A and B.
    Text in Illustration 
    *1
    		Bolt A
    *2
    		Bolt B
    *3
    		Bolt C

  1. Turn adjusting bolt C to release the tension and remove the V belt from the pulleys.



17. REMOVE NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT


A191885E01

  1. Loosen the bolt A.
    Text in Illustration 
    *1
    		Bolt A
    *2
    		Adjusting Bolt B

  1. Turn adjusting bolt B to release the tension and remove the V belt from the pulleys.



18. REMOVE BATTERY


A191829

  1. Disconnect the cables from the battery terminals.

  1. Remove the 2 nuts and the battery clamp.

  1. Remove the battery.



19. REMOVE BATTERY TRAY


A191830

  1. Remove the battery tray.



20. REMOVE NO. 2 BATTERY CARRIER


A191831

  1. Separate the harness clamp from the No. 2 battery carrier.

  1. Remove the 3 bolts and the No. 2 battery carrier.



21. REMOVE AIR CLEANER AND HOSE


A191833E01

  1. Loosen the clip and disconnect the ventilation hose.
    Text in Illustration 
    *1
    		Clamp
    *2
    		Guide

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

  1. Disengage the 2 clamps and the 2 guides, and remove the air cleaner cap.



22. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


23. DISCONNECT ENGINE WIRE


A191835E01

  1. Turn the lever and disconnect the ECM connector.
    Text in Illustration 
    *1
    		A
    *2
    		Lock Button B
    *3
    		Lever

    NOTICE:
    1. Depress the lock button B while depressing A, and turn the lever.
    2. Do not turn the lever more than 90°.
    3. Do not turn the lever before depressing the lock button B.



    A191837

  1. Disconnect the 2 connectors.



    A191838

  1. Remove the 4 connectors and 2 clamps from the engine room junction block

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



24. REMOVE FRONT BUMPER COVER


B213643E01

  1. Apply protective tape, as shown in the illustration.
    Text in Illustration 
    *1
    		Protective tape



    B213644E01

  1. Using a screwdriver, remove the 2 pin hold clips.

    HINT:
    Use the same procedure for the RH and LH sides.



    B213645

  1. Remove the 5 clips.



    B213647

  1. Remove the 4 screws.



    B213648

  1. Disengage the 6 claws and remove the front bumper cover.

  1. Disconnect the connectors.

    HINT:
    If the vehicle is equipped with fog lights, disconnect the connector.



25. DISCONNECT RADIATOR RESERVOIR TANK HOSE


A191839

  1. Separate the radiator reservoir tank hose from the hose clamp.

  1. Loosen the clip and disconnect the radiator reservoir tank hose.



26. REMOVE NO. 3 RADIATOR HOSE

  1. Loosen the 2 clips and remove the No. 3 radiator hose.



27. DISCONNECT NO. 2 RADIATOR HOSE

  1. Loosen the clip and disconnect the No. 2 radiator hose.



28. REMOVE EFI FUEL PIPE CLAMP


    A199568

  1. Remove the EFI fuel pipe clamp.



29. DISCONNECT FUEL TUBE SUB-ASSEMBLY


A199569E01

  1. Pinch the tube connector and then pull out the fuel pipe.

    NOTICE:
    1. Check that there is no dirt or mud on the pipe and around the connector before disconnecting the fuel tube connector. Clean it if necessary.
    2. If the connector and the pipe are stuck, push and pull on the connector to release them while pinching the retainer. Do not use any tools.



30. DISCONNECT HEATER WATER HOSE INLET


I104819

  1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.



31. DISCONNECT HEATER WATER HOSE OUTLET


I104820

  1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.



32. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


C195097

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



    C195142

  1. Remove the clip and separate the transmission control cable from the No. 1 transmission control cable bracket.



33. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


C198735E01

  1. Remove the 2 clips <B>.

  1. Remove the 2 <A> clips and separate the 2 cables from the transaxle.



34. DISCONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)


A204116

  1. Using a union nut wrench 10 mm, disconnect the No. 1 clutch hose from the clutch release cylinder to flexible hose tube.



35. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


A191847

  1. Separate the No. 1 fuel vapor feed hose from the hose clamp.

  1. Loosen the clip and disconnect the No. 1 fuel vapor feed hose.



36. DISCONNECT UNION TO CHECK VALVE HOSE


A191848

  1. Loosen the clip and disconnect union to check valve hose.



37. REMOVE FRONT AXLE SHAFT LH NUT


C196144E01

  1. Using SST and a hammer, release the staked part of the axle hub nut.

    SST
    09930-00010  

    NOTICE:
    1. Insert SST into the groove with the flat surface facing up.
    2. Do not damage the tip of SST using a grinder.
    3. Completely unstake the staked part before removing the axle hub nut.
    4. Do not damage the threads of the drive shaft.

  1. Using a 30 mm socket wrench, remove the axle hub nut.



38. REMOVE FRONT AXLE SHAFT RH NUT

HINT:
The removal procedure for the RH side is the same as that for the LH side.



39. SEPARATE FRONT SPEED SENSOR LH


C196521

  1. Remove the 3 bolts and separate the speed sensor and flexible hose.



    C196145

  1. Remove the bolt and separate the speed sensor from the steering knuckle.

    NOTICE:
    1. Keep the speed sensor tip and installation area free of foreign matter.
    2. Remove the speed sensor without turning it from its original installation angle.



40. SEPARATE FRONT SPEED SENSOR RH

HINT:
The removal procedure for the RH side is the same as that for the LH side.



41. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


C193209

  1. Remove the nut and separate the stabilizer link from the shock absorber.



42. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT:
The removal procedure for the RH side is the same as that for the LH side.



43. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH


C107513

  1. Remove the clip and castle nut.



    C196111E01

  1. Install SST (spacer B) to the threaded section of the lower ball joint.

    SST
    09960-20010   (09961-02060)

    NOTICE:
    Make sure the upper ends of the threaded section of the lower ball joint and SST (spacer B) are aligned.



  1. Using SST, separate the front lower suspension arm from the front axle assembly.


    C196112E01

    Text in Illustration 
    *1
    		Place the wrench here
    SST
    09960-20010   (09961-02010)

    NOTICE:
    1. Make sure to tie the string of SST to the vehicle to prevent SST from dropping.
    2. Install SST so that A and B are parallel.
    3. Be sure to place the wrench on the part indicated in the illustration.
    4. Do not damage the lower ball joint dust cover.
    5. Do not damage the drive shaft outboard joint boots.
    6. Do not damage the front disc brake dust cover.



44. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER RH

HINT:
The removal procedure for the RH side is the same as that for the LH side.



45. SEPARATE FRONT AXLE ASSEMBLY LH

  1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting between the drive shaft and front axle.

    HINT:
    If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and hammer.

  1. Push the front axle out of the vehicle to remove the drive shaft from the front axle.

    NOTICE:
    1. Do not push the front axle further out of the vehicle than is necessary.
    2. Do not damage the outboard joint boot.
    3. Do not damage the speed sensor rotor.
    4. Suspend the drive shaft with a piece of string or the equivalent.



46. SEPARATE FRONT AXLE ASSEMBLY RH

HINT:
The removal procedure for the RH side is the same as that for the LH side.



47. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


C196451E01

  1. Using SST, remove the drive shaft as shown in the illustration.

    SST
    09520-01010  
    09520-24010   (09520-32040)

    NOTICE:
    1. Do not damage the oil seal.
    2. Do not damage the inboard joint boot.
    3. Do not drop the drive shaft.



48. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    C196113

  1. Using water pump pliers, remove the bearing bracket hole snap ring.

  1. Remove the bolt and front drive shaft assembly from the drive shaft bearing bracket.

  1. Remove the drive shaft.

    NOTICE:
    1. Do not damage the oil seal.
    2. Do not damage the inboard joint boot.
    3. Do not drop the drive shaft.

    HINT:
    If it is difficult to disengage the fitting, tap the end of the front drive inboard joint assembly RH with a brass bar and hammer.



49. REMOVE FRONT FRAME ASSEMBLY


C196452E01

  1. Pass a strong rope through hole (A) in the engine mounting control bracket and tie it securely to the body.
    Text in illustration 
    *1
    		Strong Rope

    CAUTION:
    When the engine moving control rod is separated, the engine assembly moves towards the front of the vehicle and will contact components near the engine if not fastened tightly.

  1. Remove the bolt and separate the engine moving control rod from engine mounting control bracket.



    C196116

  1. Remove the 2 bolts.



    C196115E01

  1. Support the front frame assembly with 4 wooden blocks and the jack.
    Text in illustration 
    *1
    		RH Side
    *2
    		LH Side
    *3
    		Wooden Block

  1. Remove the 4 bolts and remove the front frame assembly.



50. SEPARATE SUCTION HOSE SUB-ASSEMBLY


I104976

  1. Remove the bolt and disconnect the suction hose from the compressor.

  1. Remove the O-ring from the suction hose.

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



51. SEPARATE DISCHARGE HOSE SUB-ASSEMBLY

  1. Remove the discharge hose bracket installing bolt.



    I104975

  1. Remove the bolt and disconnect the discharge hose from the compressor.

  1. Remove the O-ring from the discharge hose.

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



52. REMOVE COOLER COMPRESSOR ASSEMBLY


I104981

  1. Remove the 2 bolts and the 2 nuts.



    I104979

  1. Using a "TORX" socket wrench (E8), remove the 2 stud bolts and the compressor.



53. REMOVE ENGINE MOVING CONTROL ROD COVER (for Cold Area)


C197997

  1. Remove the 2 clips and the engine moving control rod cover.



54. REMOVE ENGINE MOVING CONTROL ROD


C196136

  1. Remove the bolt and the engine moving control rod.



55. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


A191850

  1. Disconnect the vacuum hose from vacuum switching valve.



    A203215

  1. Set the engine lifter.

    NOTICE:
    1. Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
    2. Securely suspend the engine assembly to prevent it from turning upside down, until it is secured to an engine stand.
    3. 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.

  1. Remove the rope that secures the engine assembly and the body.



    A191851

  1. Remove the 4 bolts, the 2 nuts and the engine mounting insulator RH.



    A191852

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



    A191934

  1. Install the engine hangers with the bolts, as shown in the illustration.
    Part No. 
    No. 1 Engine Hanger
    		12281-40032
    No. 2 Engine Hanger
    		12282-40020
    Bolt
    		91671-80820

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

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



56. REMOVE STARTER ASSEMBLY


    A198914

  1. Open the terminal cap.

  1. Remove the nut and disconnect the terminal 30.

  1. Disconnect the connector.

  1. Remove the 2 bolts and the starter assembly.



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


    A203227E01

  1. Use SST to hold the crankshaft pulley in place.

    SST
    09960-10010   (09962-01000, 09963-01000)



    C195071

  1. Remove the 6 drive plate and torque converter setting bolts.



58. REMOVE MANIFOLD STAY


    A199603

  1. Remove the 2 bolts, the nut and the manifold stay.



59. REMOVE AIR FUEL RATIO SENSOR


    A200970

  1. Disconnect the wire harness clamp and air fuel ratio sensor connector.



    A200972E01

  1. Using SST, remove the air fuel ratio sensor from the exhaust manifold.

    SST
    09224-00010  



60. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    A199602

  1. Remove the 3 bolts and the No. 1 exhaust manifold heat insulator.



61. REMOVE EXHAUST MANIFOLD


    A199604

  1. Remove the 2 bolts, the 4 nuts and the exhaust manifold.

  1. Remove the 2 gaskets from the cylinder head.



62. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)


    C195058

  1. Remove the 9 bolts and the CVT.

    NOTICE:
    Do not twist the CVT when removing it from the engine, because the knock pins could be damaged.



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


    A203227E01

  1. Using SST, hold the crankshaft.

    SST
    09960-10010   (09962-01000, 09963-01000)



    A191915

  1. Remove the 6 bolts and the rear spacer, drive plate and the front spacer.



64. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)


    C198742

  1. Remove the 8 bolts and the manual transaxle.



65. REMOVE BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)


    C198732

  1. Using a union nut wrench 10 mm, separate the bleeder clutch release tube.

  1. Remove the bolt and bleeder clutch release tube.



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


C195353

  1. Using a union nut wrench 10 mm, separate the clutch release bleeder from the bleeder clutch release tube.

  1. Remove the 2 bolts and clutch release bleeder.



67. REMOVE CLUTCH TUBE BOOT (for Manual Transaxle)


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


C198620

  1. Remove the 3 bolts and the clutch release with bearing cylinder assembly together with the bleeder clutch release tube.



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


C195450

  1. Using a union nut wrench 10 mm, separate the clutch release tube from the clutch release with bearing cylinder assembly.



70. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)


C195378E01
Text in Illustration 
*1
Matchmark

  1. Put the matchmarks on the clutch cover and the flywheel.

  1. Loosen each set bolt one turn at a time until the spring tension is released.

  1. Remove the set bolts and pull off the clutch cover.

    NOTICE:
    Do not drop the clutch disc.



71. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)


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


    A203227E01

  1. Using SST, hold the crankshaft.

    SST
    09960-10010   (09962-01000, 09963-01000)



    A203280

  1. Remove the 6 bolts and the flywheel sub-assembly.



73. REMOVE REAR BATTERY BRACKET REINFORCEMENT


A191853

  1. Remove the 2 bolts and the rear battery bracket reinforcement.



74. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR


A191854

  1. Remove the 5 bolts and the transverse engine engine mounting insulator.