Engine Removal

1) Set the vehicle on lift arms.
2) Open front hood fully and support with stay.
3) Release fuel pressure.





a) Disconnect fuel pump connector.
b) Start the engine, and run until it stalls.
c) After the engine stalls, crank it for five seconds more.
d) Turn ignition switch to "OFF".
e) Remove filler cap.





4) Disconnect battery ground terminal.





5) Drain coolant.
Set container under the vehicle, and remove drain cock from radiator.
6) Remove cooling system.





a) Disconnect connectors from radiator main fan and sub fan motors.





b) Disconnect radiator outlet hose from thermostat cover, and remove ATF cooler hose from clip of radiator.





c) Disconnect ATF cooler hoses from radiator.





d) Remove ATF cooler pipe from cylinder head.





e) Remove V-belt cover.





f) Disconnect radiator inlet hose from radiator.





g) Remove radiator upper bracket, and remove radiator assembly from vehicle.
7) Collect refrigerant, and remove pressure hoses. (With A/C)
a) Place and connect the attachment hose to the refrigerant recycle system.
b) Collect refrigerant from A/C system.





c) Disconnect A/C flexible hoses from A/C compressor.
8) Remove air intake system. Remove air intake duct with air cleaner case.
9) Remove air cleaner case stay.





- MT vehicles





- AT vehicles

10) Disconnect connectors, cables and hoses.








a) Disconnect the following connectors and cables.








b) Disconnect the following hoses.
11) Remove power steering pump from bracket.





a) Loosen lock bolt and slider bolt, and remove front side V-belt.





b) Remove pipe with bracket from intake manifold.





c) Remove bolts which install power steering pump from bracket.





d) Place power steering pump on the right side wheel apron.
12) Remove front exhaust pipe and center exhaust pipe.
a) Lift-up the vehicle.





b) Disconnect connector from rear oxygen sensor.





c) Remove nuts which install front exhaust pipe onto engine.





d) Separate center exhaust pipe from rear exhaust pipe.





e) Remove bolt which installs center exhaust pipe on hunger bracket.
f) Take off front and center exhaust pipes.

CAUTION: Exhaust pipe will drop when all bolts are removed. So, hold it when removing the last bolt.





13) Remove nuts which hold lower side of transmission to engine.





14) Remove nuts which install front cushion rubber onto front crossmember.





15) Separate torque converter from drive plate
(AT model)
a) Lower the vehicle.
b) Remove service hole plug.
c) Remove bolts which hold torque converter to drive plate.
d) Remove other bolts while rotating the engine using ST.
b200 cc vehicles: ST 499977300 CRANK PULLEY WRENCH
b500 cc vehicles: ST 499977100 CRANK PULLEY WRENCH





16) Remove pitching stopper.





17) Disconnect fuel delivery hose, return hose and evaporation hose.

CAUTION:
- Disconnect hose with its end wrapped with cloth to prevent fuel from splashing.
- Catch fuel from hose into container.





18) Support engine with a lifting device and wire rant.





19) Support transmission with a garage jack.

CAUTION:
Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.





20) Remove bolts which holds upper side of transmission to engine.





21) Remove engine from vehicle.
a) Slightly raise engine.
b) Raise transmission with garage jack.
c) Move engine horizontally until mainshaft is withdrawn from clutch cover.
d) Slowly move engine away from engine compartment.

CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.