Put the car on a lift.
For vehicles with air conditioning, pump out the refrigerant from the air conditioning system.
For station wagons, tilt the rear row of seats forward. Detach and lift upholstery.
Remove the fuel pump manhole cover.
Disconnect connector 1 of the fuel pump module wiring harness.
Start the engine and let it idle until it comes to a complete stop to relieve fuel pressure.
Disconnect the ground terminal from the battery.
Connect the wiring harness connector to the fuel pump module.
Install the manhole cover of the electric fuel pump.
Install and secure floor upholstery. Lower the rear (for 5-seat equipment) or middle (for 7-seat equipment) row of seats.
Remove air filter housing 3 (see How to replace the K7M engine air filter)
- - remove battery
- - remove the battery tray
Remove the controller 1. Pull the motor harness 3 out of the holder on the battery shelf.
- - lay 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 lining and side mudguards;
Unscrew the plug 1, the drain hole in the gearbox housing 2 with a key under the inner square by 8 and drain the oil.
- - drain coolant;
- - disconnect the block (two blocks - for cars with an air conditioning system) of the harness 3 of the wires from the electric fan 4 of the engine cooling system.
For vehicles with power steering, additionally disconnect block 1, wiring harness from pressure sensor 2 in the power steering system.
With a 10 socket, unscrew the bolts and nuts securing the power steering pipes on the upper part of the subframe 2, front suspension
With a head of 10, unscrew the bolts and nuts for fastening pipelines on bracket 3, fastening attachments
Unscrew the fasteners of the pipelines on the cylinder block 3 with the head 13.
Unscrew the cap of reservoir 1, power steering pump and pump out the working fluid from the system.
Open the clamp 6, disconnect the hose 4 from the pump 5 of the power steering and install the plugs in the openings of the pipeline and the pump.
Open the clamp 2, disconnect the hose 2 from the reservoir of the power steering pump and install the plugs in the openings of the hose and the reservoir.
Remove the power steering pump reservoir with hose 4 as an assembly.
Remove the hose 3. from the holder on the housing of the electric fan of the engine cooling system.
Using keys 10 and 17, unscrew the bolt 1, fastening the bracket 2, unscrew the nut 3 of the fitting, disconnect the high pressure pipeline 4 from the power steering pump 5 and install the 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 wrench, unscrew 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, the accelerator cable from the throttle pipe.
Press the latch 1 and remove the cable 4 of the accelerator drive from the bracket 3
Disconnect the wiring harness connector from the canister purge solenoid valve.
Disconnect the brake booster vacuum hose from the intake manifold, crankcase breather hose from the intake manifold, fuel pipe 1 from fuel rail 2.
For van vehicles, first cover the place of the fuel pipe connector with the fuel rail with a rag and prevent fuel from escaping when the fuel line is disconnected, since the pressure in the fuel line is maintained i.
Open the clamps 1 and disconnect the hoses 2 of the engine cooling system
Remove hoses 1, cooling systems from holders 2.
With a 13 socket with an extension, unscrew the bolts 1, fasteners and disconnect the wires 2 of the "mass" from the gearbox 3
Remove front brakes 1
With a 16 head, unscrew the nuts 2 (Figure 17) fastening the pins of the ball joints of the outer tips 3 of the steering rods and press the pins out of the steering knuckle levers 6.
Using an 18 wrench, a 18 head, we unscrew the nuts 4 of the bolts securing the shock absorber struts 5 to the steering knuckles.
Remove the bolts 7 and disconnect the shock absorber struts from the steering knuckles.
Remove the front wheel drives.
With a head of 13, we unscrew and remove the bolts 1, the upper fastening of the braces 2 of the front suspension subframe to the body.
With an 18 socket, unscrew the two bolts securing the steering gear to the front suspension subframe.
We fix the steering mechanism on the body.
If a JH3 gearbox is installed, disconnect the clutch cable 1 from the clutch release fork 2.
Disconnect the clutch cable from the clutch cable sheath stopper.
Remove the protective cover 1, the gearshift lever on the gearbox.
With a head of 10, we unscrew the bolt 2 fastening the thrust of the gearbox control drive.
We fix the linkage 3 of the gearbox control drive on the body with a hook.
If a JR5 gearbox is installed, use a flat screwdriver to disconnect the hinges 1 of the select and shift cables from the gearbox levers 2.
Disconnect the stoppers of the 3 sheaths of the select and shift cables by pressing the latches on both sides.
Disconnect the pipeline 1, hydraulic clutch from the slave cylinder 2 by pressing the latch 4. (Do not pull the latch, in case of any erroneous action, it is necessary to replace the pipeline).
Drain the brake fluid from the pipeline and plug the openings of the pipeline and the working cylinder
Remove the rear engine mount.
Disconnect the exhaust system
Move the exhaust pipe towards the rear of the vehicle and hang it to the body with hooks.
Remove the front suspension subframe
Install the traverse on the gutter grooves of the engine compartment and hook it with two hooks to the lifting eyes on the engine on the timing side and on the flywheel side.
Remove right engine mount
With a 16 socket, unscrew the nut 1 (Figure 23) of the studs securing the gearbox to the pillow 2 of the left engine mount.
Lower the engine and gearbox assembly to separate it from the left engine mount.
Using a soft metal drift, knock out key 5 of the gearbox mounting from the cushion of the left suspension support and separate the engine with gearbox assembly from the support cushion.
Unscrew the two nuts 4 with a socket 18 and remove the pillow of the left engine mount.
Install the transport trolley under the engine with gearbox.
Lower the car to the level of the trolley, install shock-absorbing pads and lower the engine with the gearbox onto the trolley.
The engine is installed in the reverse order. More details will be discussed in the next article.