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 both "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester (Click here).



1. REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

  1. Start up the engine.

  1. Switch the A/C on.

  1. Turn the blower switch to on.

  1. 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.

  1. Stop the engine.



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


    I104816E02

    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

  1. Connect the refrigerant recovery unit.

  1. 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.



2. REMOVE FRONT WHEELS


3. DRAIN ENGINE OIL


4. DRAIN MANUAL TRANSAXLE OIL

  1. Drain manual transaxle oil (Click here).



5. REMOVE ENGINE UNDER COVER


A204147

  1. Remove the 4 bolts, 4 clips and the engine under cover.



6. REMOVE NO. 3 ENGINE UNDER COVER


A198345

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



7. REMOVE FRONT FLOOR COVER LH


8. REMOVE FRONT FLOOR COVER RH


9. REMOVE RADIATOR ASSEMBLY

  1. Remove the radiator assembly (Click here).



10. REMOVE RADIATOR RESERVE TANK ASSEMBLY


A194577

  1. Remove the 2 bolts.

  1. Disconnect the air bleed valve.

  1. Disconnect the No. 5 water by-pass hose and remove the radiator reserve tank.



11. DISCONNECT NO. 2 AIR HOSE


    A202138

  1. Loosen the hose clamp and disconnect the No. 2 air hose.



12. DISCONNECT NO. 3 AIR HOSE


    A202143

  1. Loosen the hose clamp and disconnect the No. 3 air hose.



13. REMOVE INTERCOOLER ASSEMBLY


A202140

  1. Disengage the 2 wire harness clamps and separate the wire harness.



    A202141

  1. Disconnect the vacuum transmitting hose.

  1. Disconnect the intake air temperature sensor connector.



    A202145

  1. Disengage the 2 wire harness clamps.



    A202150

  1. Remove the intercooler with the intercooler air duct.



14. REMOVE COWL PANEL SUB-ASSEMBLY

  1. Remove the cowl panel sub-assembly (Click here).



15. REMOVE ENGINE COVER ASSEMBLY


    A202475

  1. Disengage the 3 claws and remove the engine cover.



16. REMOVE AIR CLEANER HOSE ASSEMBLY


A198360

  1. Remove the air cleaner hose.



17. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    A198368

  1. Remove the 2 nuts and the battery clamp.



18. REMOVE BATTERY


19. REMOVE BATTERY TRAY


20. REMOVE NO. 2 BATTERY CARRIER


A198369

  1. Disconnect the 2 wire harness clamps.

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



21. REMOVE FUEL FILTER ASSEMBLY


    A202203

  1. Disconnect the 2 wire harness clamps.

  1. Disconnect the connector.



    A202202

  1. Disconnect the 2 connectors.



    A202864

  1. Disconnect the 2 fuel hose clamps from the fuel filter.

  1. Disconnect the 2 fuel hoses.



    A202863

  1. Loosen the fuel filter drain plug to drain fuel.

  1. Tighten the fuel filter drain plug.



    A202865

  1. Remove the 2 nuts and fuel filter.



22. REMOVE INJECTION PUMP TO FUEL FILTER FUEL HOSE


A198371

  1. Disengage the hose clamp and remove the injection pump to fuel filter fuel hose.



23. DISCONNECT NO. 2 FUEL HOSE


A198373

  1. Disconnect the No. 2 fuel hose.



24. DISCONNECT ENGINE WIRE


A198379

  1. Disconnect the 3 connectors from the battery terminal.

  1. Remove the engine ground bolt.



  1. Disconnect the engine wire from the engine room junction block.

    1. Remove the junction block cover.



      2. A198380

    2. Disconnect the 4 engine wire connectors and clamp.



25. REMOVE NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)


A198353E01

  1. Loosen bolts A and B.

  1. Remove the No. 1 V belt.



26. REMOVE NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


A198395

  1. Remove the 3 bolts and the No. 2 idle pulley.



27. REMOVE FAN AND GENERATOR V BELT


A204110

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

  1. While turning the V-ribbed belt tensioner counterclockwise, align the holes, and then insert a 5 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner.



28. DISCONNECT UNION TO CONNECTOR TUBE HOSE


A198378

  1. Disconnect the union to connector tube hose.



29. DISCONNECT INLET HEATER WATER HOSE


A198375

  1. Disconnect the inlet heater water hose.



30. DISCONNECT OUTLET HEATER WATER HOSE


A198377

  1. Disconnect the outlet heater water hose.



31. REMOVE NO. 1 RADIATOR HOSE


A198384

  1. Remove the No. 1 radiator hose.



32. REMOVE NO. 2 AIR HOSE


A198390

  1. Remove the No. 2 air hose.



33. REMOVE NO. 1 AIR TUBE


A198392

  1. Remove the nut and the No. 1 air tube.



34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


A209528E01

  1. Remove the 2 clips*1 and disconnect the 2 cables from the transaxle.

  1. Remove the 2 clips*2 and disconnect the 2 cables from the control cable bracket.



35. DISCONNECT CLUTCH HOSE


A204116

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

  1. Remove the clip.



36. REMOVE TAIL EXHAUST PIPE ASSEMBLY

  1. Remove the tail exhaust pipe assembly (Click here).



37. REMOVE FRONT AXLE HUB NUT LH


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 HUB NUT RH

HINT:
Perform the same procedure as above on the opposite side.



39. SEPARATE FRONT SPEED SENSOR


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 STABILIZER LINK ASSEMBLY LH


C193209

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



41. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT:
Perform the same procedure as above on the opposite side.



42. SEPARATE TIE ROD END SUB-ASSEMBLY LH


C193211

  1. Remove the cotter pin and castle nut.



    C196109E01

  1. Install SST (spacer B) to the threaded section of the tie rod end.

    SST
    09960-20010   (09961-02060)

    NOTICE:
    Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.



  1. Using SST, separate the tie rod end from the front axle assembly.


    C196110E01

    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 ball joint dust cover.
    5. Do not damage the front disc brake dust cover.



43. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT:
Perform the same procedure as above on the opposite side.



44. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY 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.



45. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT:
Perform the same procedure as above on the opposite side.



46. 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.



47. SEPARATE FRONT AXLE ASSEMBLY RH

HINT:
Perform the same procedure as above on the opposite side.



48. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


C196454E01

  1. Using SST, remove the drive shaft.

    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.



49. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

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



50. 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.



51. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


I104977

  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. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


I104978

  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.



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


A198399

HINT:
Only perform this procedure when replacement of the engine moving control rod is necessary.

  1. Disengage the 2 clips and remove the engine moving control rod cover.



54. REMOVE ENGINE MOVING CONTROL ROD


A198400

HINT:
Only perform this procedure when replacement of the engine moving control rod is necessary.

  1. Remove the bolt and engine moving control rod.



55. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    A198361

  1. Set the engine lifter.



    A196493

  1. Remove the 5 bolts, 2 nuts and disconnect the engine mounting insulator RH.



    A198397

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

  1. Remove the engine assembly with transaxle.



    A198411E01

  1. Install the 2 engine hangers with 2 new bolts as shown in the illustration.
    Text in Illustration 
    *1
    		No. 1 Engine Hanger
    (Part No. 12281-33050)
    *2
    		Bolt
    (Part No. 91552-81050)
    *3
    		No. 2 Engine Hanger
    (Part No. 12282-33020)
    *4
    		Bolt
    (Part No. 91552-81025)

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }

    NOTICE:
    Be sure to use new bolts to install the engine hanger.

  1. Using a chain block and engine sling device, hold engine with transaxle.



56. REMOVE ENGINE MOUNTING INSULATOR RH


A202795

  1. Remove the engine mounting insulator RH.



57. REMOVE ENGINE MOUNTING INSULATOR LH


A198398

HINT:
Only perform this procedure when replacement of the engine moving mounting insulator LH is necessary.

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



58. REMOVE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


I104982

  1. Remove the 2 bolts and the 2 nuts.



    I104980

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



59. REMOVE NO. 1 AIR HOSE


A198394

  1. Remove the No. 1 air hose.



60. REMOVE NO. 5 WATER BY-PASS HOSE


A208070

  1. Remove the No. 5 water by-pass hose.



61. REMOVE NO. 2 RADIATOR HOSE


A198386

  1. Remove the No. 2 radiator hose.



62. REMOVE NO. 3 AIR HOSE


A198388

  1. Remove the No. 3 air hose.



63. REMOVE STARTER ASSEMBLY


    A198959

  1. Open the terminal cap.

  1. Remove the nut and disconnect the terminal 30.

  1. Disconnect the connector.



    A201599

  1. Remove the 2 bolts and the starter assembly.



64. REMOVE ENGINE WIRE


A198362E01

  1. Disconnect the 2 ground bolts.

  1. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.



65. REMOVE NO. 2 TURBO INSULATOR


A204145

  1. Remove the bolt, nut and the No. 2 turbo insulator.



66. REMOVE NO. 2 MANIFOLD SUPPORT BRACKET


A204143

  1. Remove the bolt, nut and the No. 2 manifold support bracket.



67. REMOVE MANIFOLD SUPPORT BRACKET


A204142

  1. Remove the 2 bolts, nut and the manifold support bracket.



68. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


A204144

  1. Remove the 3 nuts and the exhaust manifold converter.

  1. Remove the gasket from the turbocharger.



69. REMOVE CRANKSHAFT POSITION SENSOR


A202186

  1. Remove the bolt, nut and the No. 1 cylinder block insulator.

  1. Remove the crankshaft position sensor.



70. REMOVE MANUAL TRANSAXLE ASSEMBLY


    C195385

  1. Remove the 8 bolts and the manual transaxle.



71. REMOVE BLEEDER TO ACCUMULATOR TUBE


    C195334

  1. Using a union nut wrench 10 mm, remove the bleeder to accumulator tube.



72. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


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.



73. REMOVE CLUTCH TUBE BOOT

  1. Remove the clutch tube boot from the transaxle.



74. REMOVE BLEEDER CLUTCH RELEASE TUBE


C195359

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



75. REMOVE CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


C195361

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



76. REMOVE CLUTCH COVER ASSEMBLY


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.



77. REMOVE CLUTCH DISC ASSEMBLY


78. REMOVE FLYWHEEL SUB-ASSEMBLY


A208076E01

  1. Hold the crankshaft with SST.

    SST
    09213-58014  
    09330-00021  



    A198434

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



79. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


A198490

  1. Remove the No. 1 crankshaft position sensor plate.