EM-90
< REMOVAL AND INSTALLATION >[HR16DE]
ENGINE ASSEMBLY
If items or work required are not covered by the engine section, follow the procedures in the applica-
ble sections.
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-48, "
Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
Preparation
1. Remove the hood assembly. Refer to DLK-214, "Removal and Installation".
2. Remove the cowl top cover and cowl top extension assembly. Refer to EXT-20, "
Removal and Installa-
tion".
3. Release fuel pressure. Refer to EC-377, "
Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
4. Drain engine coolant from radiator. Refer to CO-11, "
Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
Never spill engine coolant on drive belt.
5. Drain the transmission fluid. Refer to TM-628, "
Draining" (M/T models), TM-171, "Changing A/T Fluid" (A/
T models).
6. Remove the following parts.
Engine undercover
Front road wheels and tires: Refer to WT-6, "
Rotation".
Front fender protector (RH and LH): Refer to EXT-22, "
Removal and Installation".
Battery and battery tray: Refer to PG-6, "
Removal and Installation".
Drive belt: Refer to EM-16, "
Removal and Installation".
Air duct and air cleaner case assembly: Refer to EM-27, "
Exploded View".
Radiator hose (upper and lower): Refer to CO-16, "
Component".
Disconnect cooling fan controller wiring harness.
Remove coolant reservoir tank.
Remove fan shroud and cooling fan assembly. Refer to CO-16, "
Component".
Engine Room LH
1. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag against foreign materials.
2. Remove ground cable at transaxle side.
3. Disconnect fuel feed hose at engine side. Refer to EM-35, "
Exploded View".
4. Disconnect EVAP purge hose and brake booster vacuum hose.
5. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-24,
"Exploded View".
6. Disconnect control linkage from transaxle. Refer to TM-189, "
Exploded View" (A/T), TM-630, "Exploded
View" (M/T).
7. Disconnect the clutch tube at transmission side. Refer to CL-12, "
Removal and Installation".
Engine Room RH
1. Remove ground cable between front cover and vehicle.
2. Remove generator and generator bracket; Refer to CHG-15, "
Removal and Installation".
3. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. (with A/C models) Refer to HA-34, "
Removal and Installation of
Compressor - HR16DE".
EM-92
< REMOVAL AND INSTALLATION >[HR16DE]
ENGINE ASSEMBLY
4. Remove engine mounting insulator (RH) (1), engine mounting
bracket (RH) (2) and engine mounting stay (3).
5. Remove engine mounting through bolt-securing nut (A).
6. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly.
CAUTION:
Make sure that no part interferes with the vehicle side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal, always be careful to prevent the vehicle from falling off the lift due to
changes in the center of gravity.
If necessary, support the vehicle by setting jack or suitable tool at the rear.
Separation
1. Remove starter motor. Refer to STR-13, "Removal and Installation".
2. Lift with a hoist and separate the engine from the transaxle assembly. Refer to EM-89, "
Exploded View".
INSTALLATION
Installation is in the reverse order of removal.
Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insu-
lator.
Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
Tighten engine mounting insulator (RH) bolts in the numerical
order shown.
InspectionINFOID:0000000001381426
INSPECTION AFTER INSTALLATION
Inspection for Leaks
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-19, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
4 : Engine mounting insulator (LH)
JPBIA0512ZZ
: Vehicle front
JPBIA0280ZZ
EM-208
< REMOVAL AND INSTALLATION >[MR18DE]
ENGINE ASSEMBLY
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-48, "
Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
1. Remove engine undercover
2. Drain engine coolant from radiator. Refer to CO-35, "
Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
Do not spill engine coolant on drive belt.
3. Remove front fender protector (RH and LH); Refer to EXT-22, "
Removal and Installation".
4. Remove exhaust front tube; Refer to EX-10, "
Component".
5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FA X - 7 , "
Removal and Installation".
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-207, "
Compo-
nent".
7. Remove rear torque rod (1).
8. Remove hood assembly. Refer to DLK-214, "
Removal and Installation".
9. Remove cowl top cover and cowl top extension assembly. Refer to EXT-20, "
Removal and Installation".
10. Release fuel pressure. Refer to EC-1035, "
Inspection".
11. Remove battery and battery tray; Refer to PG-6, "
Removal and Installation".
12. Remove drive belt; Refer to EM-142, "
Component".
13. Remove air duct and air cleaner case assembly; Refer to EM-154
.
14. Remove cooling fan assembly.
15. Remove radiator hose (upper and lower). Refer to CO-40, "
Component".
16. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag to protect against foreign materials during the operation.
17. Disconnect fuel feed hose at engine side. Refer to EM-162, "
Component".
18. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-47,
"Component".
19. Disconnect control cable from transaxle. Refer to TM-674, "
Exploded View".
20. Remove ground cable at transaxle side.
21. Remove ground cable between front cover and vehicle.
22. Remove generator. Refer to CHG-29, "
Removal and Installation".
23. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. Refer to HA-32, "
Removal and Installation of Compressor -
MR18DE".
LBIA0460E
EM-302
< REMOVAL AND INSTALLATION >[K9K]
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Exploded ViewINFOID:0000000001381504
Removal and InstallationINFOID:0000000001381505
WARNING:
Situate vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
Always be careful to work safely, avoid forceful or uninstructed operations.
Do not start working until exhaust system and coolant are cool enough.
If items or work required are not covered by the main engine section, follow the procedures in the
applicable sections.
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking rear axle, refer to GI-48, "
Garage Jack and Safety Stand
and 2-Pole Lift" or GI-49, "Board-On Lift".
REMOVAL
Description of Work
1. Engine mounting insulator LH 2. Engine mounting frame support LH 3. Engine mounting bracket LH
4. Upper torque rod 5. Engine mounting insulator RH 6. Engine mounting bracket RH (upper)
7. Engine mounting bracket RH (lower) 8. Lower torque rod bracket 9. Lower torque rod
: Vehicle front
AWBIA0162GB
GI-44
< PRECAUTION >
PRECAUTIONS
General Precaution
INFOID:0000000001606118
Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any flammable
materials. Special care should be taken when handling any flam-
mable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in a pit or other enclosed area, be sure to prop-
erly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands after handling.
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
Dispose of or recycle drained oil or the solvent used for cleaning
parts in an appropriate manner.
Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray
and possibly a fire.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
Replace inner and outer races of tapered roller bearings and needle bearings as a set.
Arrange the disassembled parts in accordance with their assembled locations and sequence.
Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents when required.
SGI285
SGI231
SEF289H
SGI233