ENGINE ASSEMBLY > REMOVAL

for Preparation Click here

HINT:

Click here

1. Loosen the lower radiator drain cock plug.
   

   CAUTION:

   Do not loosen the lower radiator drain cock plug while the engine and radiator are still hot.

   Pressurized, hot engine coolant and steam may be released and cause serious burns.

   HINT:

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

2. Remove the radiator cap.
   

3. Loosen the cylinder block drain cock plug.
   
   

   
   
   
   

HINT:

Click here for U250E.

HINT:

Click here for E351.

1. Remove the 2 nuts and No. 1 engine cover sub-assembly.
   

1. Remove the 3 bolts and separate the radiator reserve tank assembly.
   

1. Disconnect the mass air flow meter connector.
   

2. Separate the 2 wire harness clamps.
   

3. Disconnect the No. 1 vacuum switching valve connector and the 2 vacuum hoses.
   

4. Disconnect the ventilation hose.
   

5. Loosen the No. 1 air cleaner hose clamp, release the 3 air cleaner assembly clamps and remove the air cleaner cap sub-assembly with No. 1 hose.
   

1. Remove the air cleaner filter element.
   

2. Disconnect the clamp of the engine wire.
   

3. Remove the 3 bolts and air cleaner case.
   

1. Remove the bolt, nut and battery clamp.
   

2. Remove the battery and battery insulator.
   

1. Remove the battery tray.
   

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

3. Remove the 4 bolts and battery carrier.
   

1. Disconnect the 3 connectors from the engine room relay block.
   

2. Remove the 2 nuts and disconnect the wire harnesses from the engine room relay block.
   

3. Using a screwdriver, unlock the 2 claws.
   

4. Pull the engine room relay block upward.
   

5. Pull up the lever and disconnect the ECM connector.
   

6. Disconnect the clamp.
   

7. Remove the bolt and disconnect the ground cable and clamp (for Manual Transaxle).
   

8. Remove the bolt and disconnect the ground cable and clamp (for Automatic Transaxle).
   

1. Disconnect the 2 water by-pass hoses.
   

2. Disconnect the throttle body assembly connector.
   

3. Remove the 4 bolts and throttle body assembly.
   

4. Remove the gasket from the intake manifold.
   

1. Using SST, slowly turn the V-ribbed belt tensioner clockwise.
   

   SST

   09216-42010   (09216-04010)
   

2. Remove the V-ribbed belt from each pulley and slowly return the tensioner.
   

   NOTICE:

   1. Make sure that SST and other tools are set to the tensioner securely.
      
   2. When compressing the V-ribbed belt tensioner, slowly turn the tensioner.
      
   3. Be careful not to pinch your fingers between the parts.
      

1. Disconnect the generator connector.
   

2. Remove the nut and disconnect the wire harness from terminal B.
   

3. Separate the 2 wire harness clamps.
   

4. Remove the 2 bolts and generator assembly.
   

5. Remove the bolt and wire harness clamp bracket.
   

1. Disconnect the connector.
   

2. Remove the 2 bolts and 2 nuts.
   

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

   HINT:

   Secure the compressor and hoses off to the side instead of discharging the A/C system.

1. Disconnect the No. 2 radiator hose from the inlet water.
   

1. Disconnect the No. 1 radiator hose from the cylinder head.
   

1. Disconnect the 2 oil cooler hoses.
   

1. Disconnect the breather hose.
   

1. Disconnect the outlet heater water hose.
   

1. Disconnect the inlet heater water hose.
   

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

2. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
   

   NOTICE:

   1. Remove any dirt or foreign matter from the fuel tube connector before performing this work.
      
   2. Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
      
   3. Perform this work by hand. Do not use any tools.
      
   4. Do not forcibly bend, kink or twist the nylon tube.
      
   5. Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      
   6. If the fuel tube connector and pipe are stuck, push and pull to release them.
      

1. Disconnect the union to connector tube hose.
   

HINT:

Click here for E351.

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

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

3. Disconnect the control cable assembly from the control cable bracket.
   

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

2. Remove the 2 clips and disconnect the 2 transmission control cables from the transaxle*2.
   

1. Secure the steering wheel with the seat belt in order to prevent rotation.
   

   HINT:

   This operation is useful to prevent damage to the spiral cable.

1. Turn back the floor carpet, and remove the 2 clips and column hole cover silencer sheet.
   

1. Put matchmarks on the No. 2 steering intermediate shaft assembly and the steering intermediate shaft.
   

2. Remove the bolt and separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.
   

1. Remove clips A and the No. 1 steering column hole cover sub-assembly and disengage clip B from the body.
   

   NOTICE:

   Do not damage clips A and B.

1. Remove the 4 bolts and 2 compression springs.
   

2. Remove the center exhaust pipe assembly from the 2 exhaust pipe supports.
   

3. Remove the 2 gaskets.
   

1. Disconnect the heated oxygen sensor connector.
   

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

3. Remove the gasket from the exhaust manifold.
   

1. Using SST and a hammer, release the staked part of the front axle shaft nut LH.
   

   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 grinders.
      
   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 socket wrench (30 mm), remove the front axle shaft nut LH.
   

HINT:

Perform the same procedure for the LH side.

1. Remove the bolt and separate the front speed sensor and flexible hose from the front shock absorber bracket.
   

2. Remove the bolt and separate the front speed sensor from the steering knuckle.
   

   NOTICE:

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

HINT:

Perform the same procedure for the LH side.

1. Remove the cotter pin and the nut.
   

2. Install SST to the tie rod end.
   

   SST

   09960-20010   (09961-02060)
   

   NOTICE:

   Make sure that the upper ends of the tie rod end and SST are aligned.

3. Using SST, separate the tie rod end from the steering knuckle.
   
   

   
   
   
   

   SST

   09960-20010   (09961-02010)
   

   CAUTION:

   Apply grease to the threads of the bolt and the tip of SST.

   NOTICE:

   1. Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.
      
   2. Install SST with the center nut so that A and B are parallel. Otherwise, the dust cover may be damaged.
      
   3. Be sure to place the wrench on the part indicated in the illustration.
      
   4. Do not damage the front disc brake dust cover.
      
   5. Do not damage the ball joint dust cover.
      
   6. Do not damage the steering knuckle.
      

HINT:

Perform the same procedure for the LH side.

1. Remove the nut and separate the stabilizer link assembly from the front shock absorber with coil spring.
   

   NOTICE:

   If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

HINT:

Perform the same procedure for the LH side.

1. Remove the bolt and 2 nuts, and separate the front lower suspension arm from the lower ball joint.
   

HINT:

Perform the same procedure for the LH side.

1. Put matchmarks on the drive shaft and axle hub.
   

   NOTICE:

   Do not punch the marks.

2. Using a plastic-faced hammer, disconnect the front axle assembly LH.
   

   NOTICE:

   1. Be careful not to damage the boot or speed sensor rotor.
      
   2. Do not excessively push out the drive shaft from the axle assembly.
      

HINT:

Perform the same procedure for the LH side.

1. Using SST, remove the front drive shaft assembly LH.
   

   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.
      

1. Using a screwdriver, remove the snap ring from the front drive inboard joint assembly.
   

1. Remove the bearing bracket hole snap ring.
   

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

   NOTICE:

   Do not damage the boot or oil seal.

HINT:

Click here for U250E.

1. Remove the 3 bolts and 3 nuts.
   

2. Using a transmission jack or equivalent, support the front suspension crossmember sub-assembly.
   

3. Remove the 4 bolts and front suspension crossmember sub-assembly.
   
   

   
   
   
   

1. Remove the 4 bolts and center engine mounting member sub-assembly.
   

1. Set the engine assembly with transaxle on the engine lifter.
   

   NOTICE:

   Place the engine on wooden blocks or equivalent so that the engine is level.

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

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

4. Carefully remove the engine with transaxle from the vehicle.
   

1. Install the No. 1 and No. 2 engine hangers with new bolts as shown in the illustration.
   

   Torque:

   38 N*m{ 387 kgf*cm , 28 ft.*lbf }

   Item	Part No.
   No. 1 engine hanger	12281-28010
   No. 2 engine hanger	12282-28010 or 12282-AB010
   Bolt	90080-10177

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

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

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

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

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

1. Remove the 3 bolts and bracket.
   

1. Disconnect the terminal 50 connector from the starter assembly.
   

2. Remove the nut and disconnect the wire harness from terminal 30.
   

3. Remove the 2 bolts, wire harness clamp bracket and starter assembly.
   

1. Disconnect the terminal 50 connector from the starter assembly.
   

2. Remove the nut and disconnect the wire harness from terminal 30.
   

3. Remove the 3 bolts, clutch accumulator bracket, wire harness clamp bracket and starter assembly.
   

HINT:

Click here for E351.

HINT:

Click here for U250E.

HINT:

Click here for E351.

HINT:

Click here for E351.

1. Using SST, hold the crankshaft.
   

   SST

   09213-54015   (91651-60855)
   09330-00021  
   

2. Remove the 8 bolts and flywheel.
   

1. Using SST, hold the crankshaft.
   

   SST

   09213-54015   (91651-60855)
   09330-00021  
   

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