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 during the operation.

Disconnect fuel feed hose at engine side. Refer to

EM-155, "Exploded View"

Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to

CO-44,

"Exploded View"

Disconnect control cable from transaxle. Refer to

TM-330, "Exploded View"

Remove ground cable at transaxle side.

Engine Room RH

Disconnect vacuum hose from intake manifold. Refer to

EM-146, "Exploded View"

Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope (with A/C
models). Refer to

HA-39, "Exploded View"

Disconnect reservoir tank hoses. Refer to

CO-34, "Exploded View"

Vehicle Underbody

Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to

BRC-67, "FRONT

WHEEL SENSOR : Exploded View"

Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to

BR-37, "BRAKE CALIPER ASSEMBLY : Exploded

View"

Disconnect steering outer sockets from steering knuckle. Refer to

ST-13, "Exploded View"

Remove rear torque rod.

Remove drive shafts (LH and RH). Refer to

FAX-22, "MR20DE MODELS : Exploded View"

(2WD models)

FAX-55, "Exploded View"

(4WD models).

Remove propeller shaft (4WD models). Refer to

DLN-110, "Exploded View"

Remove stabilizer connecting rod. Refer to

FSU-16, "Exploded View"

Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to

ST-10, "Exploded View"

Remove front suspension member. Refer to

FSU-16, "Exploded View"

10. Preparation for the separation work of transaxle is as follows:

• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to

EM-152, "Exploded

View"

ENGINE ASSEMBLY

EM-201

< REMOVAL AND INSTALLATION >

[MR20DE]

Removal

Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of the engine and the transaxle assembly.

CAUTION:

Put a piece of wood or an equivalent as the supporting sur-
face, secure a completely stable condition.

Remove four mounting bolts on engine mounting insulator (RH) (front cover side).

Remove two mounting bolts (A) on engine mounting insulator
(LH) (transaxle side).

CAUTION:

Never remove the bolt (B) coupling insulator and bracket.
(part not for disassembly)

Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.

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

Install engine slinger to front cover front left side and cylinder
head rear right side.

Remove starter motor. Refer to

STR-25, "MR20DE MODELS : Exploded View"

Lift with a hoist and separate the engine from the transaxle assembly. Refer to

TM-351, "2WD : Exploded

View"

(2WD models) or

TM-354, "4WD : Exploded View"

(4WD models).

INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:

• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-

ing insulator.

• Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts.

Engine mounting insulator (RH)

PBIC1190E

:Vehicle front

JPBIA0463ZZ

: Engine front

Slinger bolts

Front cover side:

: 32.9 N·m (3.4 kg-m, 24 ft-lb)

Cylinder head side:

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

PBIC3222J

EM-202

< REMOVAL AND INSTALLATION >

[MR20DE]

ENGINE ASSEMBLY

• Install engine mounting insulator (RH) to the engine side according to the following procedure.

Temporarily tighten mounting bolts the engine mounting insula-
tor (RH) and the engine.

Tighten mounting bolts in the numerical order shown in the fig-
ure.

Engine mounting insulator (LH)

• Install engine mounting insulator (LH) to the transaxle side according to the following procedure.

Temporarily tighten the mounting bolt (A).

Tighten mounting bolt (B) to the specified torque.

Tighten mounting bolt (A) to the specified torque.

CVT : Inspection

INFOID:0000000000893964

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-21, "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.

Summary of the inspection items:

* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

:Vehicle front

PBIC3224J

:Vehicle front

JPBIA0462ZZ

Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Fuel

Leakage

Exhaust gases

—

Leakage

—

ENGINE STAND SETTING

EM-203

< DISASSEMBLY AND ASSEMBLY >

[MR20DE]

DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING

Setting

INFOID:0000000000893965

NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1.

Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to

EM-194, "M/T : Exploded View"

(M/T models) or

EM-198, "CVT : Exploded View"

(CVT

models).

Install engine to engine stand with the following procedure:

Remove flywheel (M/T models) or drive plate (1) (CVT models).
• Secure flywheel or drive plate with a stopper plate [SST:

KV11105210] (A), and remove mounting bolts.

CAUTION:

• Never disassemble them.
• Never place them with signal plate facing down.
• When handling signal plate, take care not to damage or

scratch them.

• Handle signal plate in a manner that prevents them from

becoming magnetized.

NOTE:
This figure shows CVT models as an example.

Lift the engine with a hoist to install it onto widely use engine stand.

CAUTION:

• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large

enough for supporting the engine weight.

• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-

tial risk of overturning stand.

- Intake manifold: Refer to

EM-146, "Exploded View"

- Exhaust manifold: Refer to

EM-149, "Exploded View"

- Rocker cover: Refer to

EM-160, "Exploded View"

NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T
models) or drive plate (CVT models) removed.

CAUTION:

Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.

Drain engine oil. Refer to

LU-15, "Draining"

CAUTION:

Be sure to clean drain plug and install with new washer.

PBIC3226J

PBIC3227J

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