ENGINE ASSEMBLY > REMOVAL

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NOTICE:

When the manual 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.

1. Start up the engine.
   

2. Switch the A/C on.
   

3. Turn the blower switch to on.
   

4. Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the remaining compressor oil from each component, in the cooler compressor.
   

5. Stop the engine.
   

6. Remove the caps from the service valves on the refrigerant line.
   
   

   
   
   
   

   Text in illustration 

   *a	Engine room side
   *b	Wheel house side

   Access to Hi Pressure Side 

   Engine Type	RHD	LHD
   1KR-FE	Engine room	Engine room
   1NR-FE	Engine room	Engine room
   1ND-TV	Engine room	Engine room

   Access to Low Pressure Side 

   Engine Type	RHD	LHD
   1KR-FE	Wheel house	Wheel house
   1NR-FE	Wheel house	Wheel house
   1ND-TV	Wheel house	Wheel house

7. Connect the refrigerant recovery unit.
   

8. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.
   

   HINT:

   Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

CAUTION:

To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator 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.

2. Remove the water filler cap sub-assembly.
   

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

2. 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

3. Using a socket hexagon wrench (6 mm), install the No. 1 transmission oil filler tube.
   

   Torque:

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

4. 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.

1. Stop the vehicle in a level place.
   

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

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

1. Apply protective tape, as shown in the illustration.
   

   Text in Illustration 

   *1	Protective tape

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

   HINT:

   Use the same procedure for the RH and LH sides.

3. Remove the 5 clips.
   

4. Remove the 4 screws.
   

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

6. Disconnect the connectors.
   

   HINT:

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

1. Remove the 14 screws and front bumper energy absorber.
   

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

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

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

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

1. Loosen the bolt A.
   

2. Turn adjusting bolt B to release the tension and remove the No. 1 V-ribbed belt from the pulleys.
   

1. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and remove the V-ribbed belt from the V-ribbed belt tensioner.
   

2. While turning the V-ribbed belt tensioner counterclockwise, align the holes, and then insert a 4 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner in place.
   

1. Disconnect the cables from the battery terminals.
   

2. Remove the 2 nuts and the battery clamp.
   

3. Remove the battery.
   

1. Remove the battery tray.
   

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

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

1. Disconnect the wire harness clamp and the intake mass air flow meter connector.
   

2. Disconnect the ventilation hose.
   

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

4. Disengage the 2 clamps and 2 guides and remove the air cleaner and hose.
   

   Text in Illustration 

   *1	Clamp
   *2	Guide

1. Turn the lever and disconnect the ECM connector.
   

   Text in Illustration 

   *1	Lock Button B
   *2	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.
      

2. Disconnect the 2 connectors from the battery terminal.
   

3. Remove the engine room junction block cover.
   

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

5. Remove the ground bolt and harness clamp and disconnect the engine wire.
   

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

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

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

1. Loosen the clamp and disconnect the radiator hose from the radiator assembly.
   

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

1. Remove the EFI fuel pipe clamp.
   

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

   NOTICE:

   1. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      
   2. The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      
   3. If the connector and the pipe are stuck, push and pull on the connector to release them while pinching the retainer. Pull the connector out of the pipe carefully.
      
   4. Do not use any tools.
      
   5. Do not bend or twist the tubes.
      
   6. Protect the contact surface by covering it with a plastic bag.
      
   7. Do not damage any of the clips. If a clip is damaged, replace it.
      

1. Loosen the clip and disconnect the inlet heater water hose.
   

1. Loosen the clip and disconnect the outlet heater water hose.
   

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

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

1. Remove the 2 clips <B>.
   

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

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

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

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.
      

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

HINT:

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

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

2. 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.
      

HINT:

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

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

HINT:

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

1. Remove the clip and castle nut.
   

2. 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.

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

   
   
   
   

   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.
      

HINT:

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

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.

2. 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.
      

HINT:

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

1. Remove the 2 bolts and the 2 nuts, and the drive shaft heat insulator.
   

1. Using a screwdriver and hammer, 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:

Use the same procedure for the RH side as for the LH side.

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.

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

3. Remove the 2 bolts.
   

4. Support the front frame assembly with 4 wooden blocks and the jack.
   

   Text in illustration 

   *1	RH Side
   *2	LH Side
   *3	Wooden Block

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

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

2. 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.

3. Remove the bolt and the separate the discharge hose.
   

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

2. 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.

1. Remove the 2 bolts and the 2 nuts.
   

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

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

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

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.
      

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

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

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

5. Install the engine hangers with the bolts, as shown in the illustration.
   

   Text in Illustration 

   *1	No. 1 Engine Hanger (Part No. 12281-47010)
   *2	No. 2 Engine Hanger (Part No. 12282-47010)
   *3	Bolt (Part No. 91552-81040)

   Torque:

   43 N*m{ 438 kgf*cm , 31 ft.*lbf }

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

1. Disengage the clamp and separate the breather hose from the water by-pass hose.
   

2. Remove the bolt and separate the water by-passe hose from the CVT.
   

3. Loosen the 2 clips and separate the 2 water by-pass hoses from the oil cooler.
   

4. Disengage the hose clamp.
   

5. Loosen the 2 clip and remove the water by-pass hose.
   

1. Disengage the hose clamp.
   

2. Loosen the clip and remove the water by-pass hose.
   

1. Loosen the clip and remove the inlet heater water hose.
   

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

1. Remove the bolt and the water filler.
   

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

1. Remove the 2 ground bolts and separate the ground wire from the cylinder block.
   

2. Remove the nut from the starter.
   

3. Remove the bolt and separate the engine wire from the wiring harness bracket.
   

4. Remove the terminal cap from the generator.
   

5. Remove the nut from the generator.
   

6. Remove the ground bolt and separate the ground wire from the transaxle.
   

   Text in Illustration 

   *A	CVT
   *B	Manual Transaxle

7. Disconnect all of the clamps and connectors and remove the engine wire from the engine assembly with transaxle.
   

1. Remove the 2 bolts and remove the drive shaft heat insulator bracket from the engine.
   

1. Disengage the claw by pulling it outward and remove the flywheel housing side cover.
   

1. Open the terminal cap.
   

2. Remove the nut and disconnect terminal 30.
   

3. Disconnect the connector.
   

4. Remove the 2 bolts and the starter assembly.
   

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

   SST

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

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

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.

1. Using SST, hold the crankshaft.
   

   SST

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

2. Remove the 8 bolts, the rear drive plate spacer, the drive plate and the front drive plate spacer.
   

1. Remove the 8 bolts and the manual transaxle.
   

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

2. Remove the bolt and bleeder clutch release tube.
   

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

2. Remove the 2 bolts and clutch release bleeder.
   

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

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

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

   Text in Illustration 

   *a

   Matchmark

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

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

   NOTICE:

   Do not drop the clutch disc.

1. Using SST, hold the crankshaft.
   

   SST

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

2. Remove the 8 bolts, the rear flywheel plate spacer, the flywheel and the front flywheel plate spacer.
   

1. Using a knife, cut off the lip of the inner oil seal.
   

   Text in Illustration 

   *1	Protective Tape
   *a	Cut Position
   *b	Pry Out

2. Using a screwdriver with its tip wrapped with protective tape, pry out the inner oil seal.
   

   NOTICE:

   Be careful not to damage the one-way clutch assembly.

1. Turn the one-way clutch assembly counterclockwise while removing it.
   

1. Remove the one-way clutch O-ring from the crankshaft.
   

1. Visually check the one-way clutch assembly installation surface for damage, deformation, and cracks.
   

2. Check that the snap ring is not broken and fits correctly into the crankshaft bearing groove.
   

1. Using a screwdriver, remove the snap ring.
   

2. Remove the ring gear sub-assembly from the crankshaft.
   

   NOTICE:

   Do not forcefully pry the ring gear during removal.

1. Make sure that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
   

   Text in Illustration 

   *a	Lock
   *b	Free

   If the one-way clutch assembly does not operate normally, replace it.
   

HINT:

Only perform this procedure when replacement of the engine moving mounting insulator RH is necessary.

1. Remove the 3 bolts and the transverse engine engine mounting insulator.
   

HINT:

Only perform this procedure when replacement of the transverse engine engine mounting insulator is necessary.

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