Engine Removal (With ETCS)

Engine Removal

Special Tools Required
Engine tilt hanger set (  07KAK-SJ40101)
 

NOTE:

• Use fender covers to avoid damaging painted surfeces.
  
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  
• Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
  

1.	Secure the hood in the wide open position (support rod in the lower hole).

2.	Disconnect the battery negative cable first, then the positive cable .

3.	Remove the battery.

4.	Remove air cleaner housing.

5.	Remove the harness clamps (A), then remove the battery base (B).   BA

6.	Disconnect the engine control module (ECM) connectors (A) and main wire harness connector (B). LHD models:  BA RHD models:  AB

7.	Disconnect the accelerator pedal position (APP) sensor connector (A) . LHD models:  BABC RHD models:  BCAB

8.	Remove the harness clamps (B) and grommet (C), then pull the engine wire harness through the bulkhead.

9.	Remove the battery cables (A) from the under-hood fuse/relay box, then remove the harness clamp(s) (B). LHD models:  CBA RHD models:  ABC

10.	Disconnect the wire harness connector (C).

11.	Relieve fuel pressure.

12.	Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).   AB

13.	Remove the shift cable (A) and select cable (B). Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.   BA

14.	Remove the clutch slave cylinder (A) and clutch line bracket mounting bolt (B). Do not operate the clutch pedal once the slave cylinder has been removed.   BA

15.	If the A/C compressor is equipped, remove the drive belt, refer to the 2002 Jazz/Fit Shop Manual.

16.	Remove the radiator cap.

17.	Raise the hoist to full height.

18.	Remove the front tires/wheels.

19.	Remove the splash shield.

20.	Loosen the drain plug in the radiator to drain the engine coolant, refer to the 2002 Jazz/Fit Shop Manual.

21.	Drain the transmission fluid.

22.	Drain the engine oil, refer to the 2002 Jazz/Fit Shop Manual.

23.	Disconnect the primary heated oxygen sensor (primary HO2S) connector (A) .   ACB

24.	Disconnect the secondary heated oxygen sensor (secondary HO2S) connector (B) .

25.	Remove the three way catalytic converter (TWC)(C).

26.	Disconnect the stabilizer links.

27.	Disconnect the suspension lower arm ball joints.

28.	Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.

29.	Remove the steering gearbox from the front subframe.

30.	Disconnect the compressor clutch connector (A), then remove the A/C compressor (B) without disconnecting the A/C hoses.   AB

31.	If the A/C compressor is equipped, remove the condenser fan shroud.

32.	Lower the hoist.

33.	Remove the upper radiator hose (A) and lower radiator hose (B).   AB

34.	Remove the heater hoses.

35.	Attach the engine tilt hanger set (Commercially available tool for EU models) to the engine as shown.   07KAK-SJ40101

36.	Remove the ground cable (A), then remove the transmission mount bracket (B).   BA

37.	Remove the ground cable (A), then remove the side engine mount/bracket assembly (B).   AB

38.	Make sure the hoist brackets are positioned properly. Raise the hoist to full height.

39.	Remove the rear mount mounting bolts.

40.	Remove the left front mount/bracket assembly.

41.	Remove the two clips (A) securing the under covers, then remove the front subframe (B).   AAB

42.	Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.

43.	Slowly lower the engine about 150 mm (6 in.). Check once again that all hoses and wires are disconnected from the engine/transmission.

44.	Lower the engine all the way. Remove the chain hoist from the engine.

45.	Remove the engine from under the vehicle.