Place the vehicle on a lift
For vehicles with air conditioning, bleed the refrigerant from the air conditioning system.
For station wagons, tilt the rear row of seats forward.
Disconnect and lift the floor trim.
Remove the electric fuel pump hatch cover.
Disconnect connector 1 of the electric fuel pump module wiring harness.
Start the engine and let it run at idle speed until it stops completely to relieve fuel pressure.
Disconnect the ground terminal from the battery.
Connect the connector of the wiring harness to the fuel pump module.
Install the electric fuel pump hatch cover. Install and secure the floor trim.
Lower the rear (for 5-seater configuration) or middle (for 7-seater configuration) row of seats.
Remove housing 3 of the air filter (see the article on removing the filter)
- - remove the battery battery
- - remove the battery tray
Remove the controller 1. Remove the 3 engine wiring harness from the mount on the battery shelf.
- - place the wiring harness with fuses and relays on the engine;
- - remove the front wheels;
- - unscrew the hub nuts;
- - remove the engine crankcase protection;
- - remove the inner linings and side mudguards;
Using an 8 mm square wrench, unscrew the plug 1, the drain hole in the gearbox housing 2 and drain the oil.
- - drain the coolant;
- - disconnect the block (two blocks - for cars with an air conditioning system) of the wiring harness 3 from the electric fan 4 of the engine cooling system.
For vehicles with power steering, additionally disconnect connector 1, wiring harness from the pressure sensor 2 in the power steering system.
Using a 10 mm socket, loosen the bolts and nuts securing the power steering pipelines on the upper part of subframe 2, front suspension
Using a 10 mm socket, unscrew the bolts and nuts securing the pipes to bracket 3, mounting the attachment units
Using a 13 mm socket, loosen the pipe fasteners on cylinder block 3.
Unscrew the cap of reservoir 1, the power steering pump and pump out the working fluid from the system.
Loosen clamp 6, disconnect hose 4 from pump 5 of the power steering and install plugs in the holes of the pipeline and pump.
Loosen clamp 2, disconnect hose 2 from the reservoir of the power steering pump and install plugs in the holes of the hose and reservoir.
Remove the reservoir of the power steering pump with hose 4 in assembly.
Remove hose 3. from the holder on the housing of the electric fan of the engine cooling system.
Using keys for 10 and 17, unscrew bolt 1, fastening bracket 2, unscrew nut 3 of the fitting, disconnect high-pressure pipeline 4 from the pump 5 of the power steering and install plugs in the openings of the pipeline and the power steering pump.
For vehicles with air conditioning, disconnect connector 1, wiring harness from refrigerant pressure sensor 2.
Using a 10 mm wrench, loosen the bolt securing the pipeline to the air conditioning compressor, disconnect the pipeline from the compressor and install the plugs.
Disconnect the ball end 1, accelerator drive cable from the throttle pipe. Press the lock 1 and remove the accelerator drive cable 4 from the bracket 3.
Disconnect the wiring harness connector from the solenoid valve of the adsorber purge.
Disconnect the brake booster vacuum hose from the intake manifold, the crankcase ventilation hose from the intake manifold, fuel pipe 1 from fuel rail 2.
For vans, first cover the place of the fuel pipe connector with a rag and prevent fuel from escaping when disconnecting the fuel line, since the pressure in the fuel line is maintained.
Unclamp clamps 1, and disconnect hoses 2 of the engine cooling system
Remove hoses 1, cooling system from holders 2
Using a 13 mm socket with an extension, unscrew bolts 1, mountings and disconnect wires 2 "ground" from the gearbox
Remove the front brakes 1.
Using a 16 mm head, unscrew the nuts 2 (Figure 17) securing the ball joint pins of the outer ends 3 of the steering rods and press the pins out of the steering knuckle arms 6.
Using a 18 mm wrench and an 18 mm head, unscrew the nuts 4 securing the shock absorber struts 5 to the steering knuckles. Remove bolts 7 and disconnect the shock absorber struts from the steering knuckles.
Remove the front wheel drives.
Using a 13 mm head, unscrew and remove bolts 1 (Fig. 18) for the upper fastening of the struts 2 of the front suspension subframe to the body.
Using a 18 mm head, unscrew the two bolts securing the steering gear to the front suspension subframe.
Secure the steering gear to the body.
If the JH3 gearbox is installed, disconnect clutch cable 1 from clutch release fork 2.
Disconnect the clutch cable from the clutch cable housing stopper.
Remove protective cover 1, gear shift lever on the gearbox.
Using a 10 head, unscrew bolt 2 securing the gearbox control rod.
Secure rod 3 of the gearbox control drive to the body using a hook.
If the JR5 gearbox is installed, use a flat-head screwdriver to disconnect the joints 1 of the gear selection and shift cables from the gearbox levers 2.
Disconnect the stoppers 3 of the gear selection and shift cable sheaths by pressing the locks on both sides.
Drain the brake fluid22.
Disconnect the pipeline 1, clutch hydraulic drive from the slave cylinder 2, by pressing the lock 4. (Do not pull the lock, if any erroneous action is made, the pipeline must be replaced). from the pipeline and plug the holes in the pipeline and the slave cylinder.
Remove the rear engine mount, article - "How to replace the K4M power plant mounts"
Disconnect the exhaust system, see the article - "How to replace the K7M exhaust manifold gasket"
Move the exhaust pipe towards the rear of the car and hang it on the body using hooks.
Remove the front suspension subframe
Install a crossmember on the gutters of the engine compartment and hook it with two hooks to the lifting eyes on the engine on the timing belt side and on the flywheel side.
Remove the right engine mount support
Using a 16 mm head, loosen nut 1 (Figure 23) of the gearbox mounting stud to cushion 2 of the left engine mount.
Lower the engine and gearbox assembly to separate it from the left engine mount.
Using a soft metal punch, knock out key 5 of the gearbox mounting from the left engine mount cushion and separate the engine and gearbox assembly from the mount cushion.
Using an 18 mm head, loosen two nuts 4 and remove the left engine mount cushion.
Install a transport trolley under the engine and gearbox.
Lower the vehicle to the level of the trolley, install shock-absorbing pads and lower the engine and gearbox onto cart.
The engine is installed in the reverse order. This will be discussed in more detail in the next article.