Removal and Installation
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE ENGINE UNDER COVER LH
4. DRAIN ENGINE COOLANT
5. REMOVE FRONT WHEELS
6. REMOVE RADIATOR GRILLE
7. REMOVE FRONT BUMPER COVER
8. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 4 nuts and cylinder head cover No.2.
9. REMOVE BATTERY
10. REMOVE AIR CLEANER ASSY
11. DISCONNECT FUEL TUBE SUB-ASSY
SST 09268-21010
12. DISCONNECT ACCELERATOR CONTROL CABLE ASSY
13. REMOVE RADIATOR ASSY
14. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (MANUAL TRANSAXLE)
15. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (AUTOMATIC TRANSAXLE)
16. SEPARATE CLUTCH RELEASE CYLINDER ASSY (MANUAL TRANSAXLE)
17. DISCONNECT UNION TO CHECK VALVE HOSE
a. Disconnect the union to check valve hose from the brake booster.
18. DISCONNECT HEATER WATER INLET HOSE A
a. Disconnect the heater water inlet hose from the air conditioner tube.
19. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
a. Disconnect the heater water outlet hose from the air conditioner tube.
20. DISCONNECT ENGINE WIRE
a. Remove the glove compartment door.
b. Disconnect the engine wire harness from the ECM and junction block.
c. Pull out the engine wire.
d. Disconnect the engine wire from the engine room junction block.
e. Remove the body ground.
21. REMOVE FAN AND GENERATOR V-BELT
22. REMOVE A/C COMPRESSOR
HINT: Secure the hoses off to the side instead of detaching.
23. REMOVE FLOOR PANEL BRACE FRONT
24. REMOVE EXHAUST PIPE ASSY FRONT
25. SEPARATE STEERING INTERMEDIATE SHAFT ASSY
26. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, remove the lock nut.
SST 09930-00010
NOTICE:
^ When removing the nut, remove the lock nut completely.
^ Do not damage the threads of the drive shaft.
^ Do not use SST with its tip sharpened.
^ Set SST in the groove with the flat face facing upward.
b. Using a 30 mm socket wrench, remove the lock nut.
HINT: Perform the same procedure as above on the opposite side.
27. DISCONNECT SPEED SENSOR FRONT LH (W/ ABS)
a. Remove the bolt, disconnect the speed sensor from the steering knuckle.
HINT: Perform the same procedure as above on the opposite side.
28. SEPARATE TIE ROD END SUB-ASSY LH
a. Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011
NOTICE: Do not damage the dust cover of the ball joint.
HINT: Perform the same procedure as above on the opposite side.
29. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Using SST, disconnect the front suspension arm lower from the steering knuckle.
SST 09628-00011
HINT: Perform the same procedure as above on the opposite side.
30. SEPARATE FRONT DRIVE SHAFT ASSY LH
a. Using a plastic hammer, detach the drive shaft from the axle hub by tapping.
HINT: Perform the same procedure as above on the opposite side.
31. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the bolt which is used to fix the liquid tube to the engine mounting insulator RH.
c. Remove the 5 bolts and nut, and then remove the engine mounting insulator RH.
d. Remove the 2 bolts and detach the engine mounting bracket from the engine mounting insulator LH.
e. Remove the engine together with the transaxle.
1. Remove the 8 bolts shown in the illustration.
2. Carefully remove the engine assembly from the vehicle.
f. Remove the bolt and condenser.
g. Install the 2 engine hangers as shown in the illustration.
Parts No.:
No. 1 engine hanger 12281-21010
Bolt 91642-81025
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
h. Attach the engine sling and hang the engine with the chain block.
32. REMOVE VANE PUMP V-BELT
33. REMOVE VANE PUMP ASSY
a. Disconnect the power steering oil pressure sensor harness.
b. Remove the 2 bolts and vane pump assembly.
34. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Remove the through bolt.
b. Separate the engine and transaxle assembly from the suspension crossmember.
35. REMOVE STARTER ASSY
36. REMOVE GENERATOR ASSY
37. REMOVE MANUAL TRANSAXLE ASSY (MANUAL TRANSAXLE)
38. REMOVE AUTOMATIC TRANSAXLE ASSY (AUTOMATIC TRANSAXLE)
39. REMOVE CLUTCH COVER ASSY (MANUAL TRANSAXLE)
40. REMOVE CLUTCH DISC ASSY (MANUAL TRANSAXLE)
41. REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL
SST 09330-00021, 09213-58012 (91111-50845)
42. REMOVE VENTILATION HOSE
43. REMOVE VENTILATION HOSE NO.2
44. REMOVE INTAKE MANIFOLD
a. Using several steps, remove the 3 bolts and 2 nuts in the sequence shown in the illustration, then remove the intake manifold.
b. Remove the gasket from the intake manifold.
45. REMOVE BOOSTER VACUUM TUBE
a. Remove the 2 bolts and booster vacuum tube.
46. REMOVE MANIFOLD SUPPORT BRACKET
a. Remove the 3 bolts and manifold support bracket.
47. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Remove the 4 bolts and exhaust manifold heat insulator.
48. REMOVE EXHAUST MANIFOLD
a. Remove the 3 bolts and 2 nuts, and then remove the exhaust manifold.
49. REMOVE IGNITION COIL NO.1
a. Remove the 4 bolts and pull out the 4 ignition coils.
50. REMOVE WATER BYPASS PIPE NO.1
a. Remove the 2 nuts and 2 bolts, and then remove the water bypass pipe.
51. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using SST, remove the engine coolant temperature sensor.
SST 09817-33190
52. REMOVE KNOCK SENSOR
a. Using SST, remove the knock sensor.
SST 09816-30010
53. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Using SST, remove the oil pressure switch.
SST 09268-46021
54. REPLACE PARTIAL ENGINE ASSY
55. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install the oil pressure switch.
SST 09268-46021
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
NOTICE: Do not start the engine for at least 1 hour after installation.
56. INSTALL KNOCK SENSOR
a. Using SST, install the knock sensor.
SST 09816-30010
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
57. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket onto the engine coolant temperature sensor.
b. Using SST, fix the engine coolant temperature sensor.
SST 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
58. INSTALL WATER BYPASS PIPE NO.1
a. Install a new gasket and the water bypass pipe with the 2 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
59. INSTALL IGNITION COIL NO.1
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
60. INSTALL EXHAUST MANIFOLD
a. Using several steps, install a new exhaust manifold gasket and the exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
61. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the exhaust manifold heat insulator No.1 with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
62. INSTALL MANIFOLD SUPPORT BRACKET
a. Install the manifold support bracket with the 3 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
63. INSTALL BOOSTER VACUUM TUBE
a. Install the booster vacuum tube with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
64. INSTALL INTAKE MANIFOLD
a. Install a new gasket onto the intake manifold.
b. Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
65. INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL
SST 09213-58012 (91111-50845), 09330-00021
66. INSTALL CLUTCH DISC ASSY (MANUAL TRANSAXLE)
67. INSTALL CLUTCH COVER ASSY (MANUAL TRANSAXLE)
68. INSTALL MANUAL TRANSAXLE ASSY (MANUAL TRANSAXLE)
69. INSTALL AUTOMATIC TRANSAXLE ASSY (AUTOMATIC TRANSAXLE)
70. INSTALL GENERATOR ASSY
71. INSTALL STARTER ASSY
72. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Fasten the bolt to secure the engine and transaxle assembly to the suspension crossmember.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
73. INSTALL VANE PUMP ASSY
a. Install the vane pump assembly with the 2 bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)
HINT: After adjusting the V-ribbed belt, first tighten bolt A, then tighten bolt B.
74. INSTALL VANE PUMP V-BELT
a. Temporarily install the V-ribbed belt on each pulley.
75. ADJUST VANE PUMP V-BELT
76. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine with the transaxle on the engine lifter.
b. Install the engine with the transaxle onto the engine compartment.
c. Temporarily install the suspension crossmember with the 8 bolts.
d. Install the engine mounting bracket LH onto the engine mounting insulator LH with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
e. Install the engine mounting insulator RH with the 5 bolts and nut.
Torque:
Bolt A 45 Nm (459 kgf-cm, 33 ft. lbs.)
Bolt B 52 Nm (530 kgf-cm, 38 ft. lbs.)
Nut 52 Nm (530 kgf-cm, 38 ft. lbs.)
f. Install the liquid tube with the bolt.
Torque:
Bolt C 9.8 Nm (100 kgf-cm, 7.2 ft. lbs.)
g. Insert SST into the positioning holes of the right hand crossmember and vehicle.
SST 09670-00010
h. Temporarily tighten bolt A, then tighten bolt B.
i. Insert SST into the positioning holes of the lefthand crossmember and vehicle.
SST 09670-00010
j. Temporarily tighten bolt A, then tighten bolt B.
k. Insert SST into the positioning holes of the righthand crossmember and vehicle again, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
Bolt A 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B 70 Nm (714 kgf-cm, 52 ft. lbs.)
l. Insert SST into the positioning holes of the left-handle crossmember and vehicle again, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
Bolt A 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B 70 Nm (714 kgf-cm, 52 ft. lbs.)
m. Tighten the 4 bolts shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
77. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Install the front suspension arm lower onto the steering knuckle with the nut.
Torque: 98 Nm (999 kgf-cm, 72 ft. lbs.)
b. Install a new clip.
HINT: Perform the same procedure as above on the opposite side.
78. INSTALL TIE ROD END SUB-ASSY LH
a. Connect the tie rod end to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Install a new cotter pin.
NOTICE:
^ Be careful of the threads and tapered portions of the tie rod end not to make contact with oils.
^ After tightening the castle nut, turn it clockwise within 60° to align the pin holes for the cotter pin.
HINT: Perform the same procedure as above on the opposite side.
79. CONNECT SPEED SENSOR FRONT LH (W/ ABS)
a. Install the speed sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
HINT: Perform the same procedure as above on the opposite side.
80. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install the new hub nut.
Torque: 216 Nm (2,203 kgf-cm, 160 ft. lbs.)
b. Using a chisel, stake the hub nut.
HINT: Perform the same procedure as above on the opposite side.
81. INSTALL STEERING INTERMEDIATE SHAFT ASSY
82. INSTALL EXHAUST PIPE ASSY FRONT
83. INSTALL FLOOR PANEL BRACE FRONT
84. INSTALL A/C COMPRESSOR
85. INSTALL FAN AND GENERATOR V-BELT
a. Temporarily install the V-ribbed belt on each pulley.
86. ADJUST FAN AND GENERATOR V-BELT
87. INSTALL RADIATOR ASSY
88. CONNECT FUEL TUBE SUB-ASSY
89. INSTALL AIR CLEANER ASSY
90. INSTALL CYLINDER HEAD COVER NO.2
a. First tighten A nuts, then tighten bolts B.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
91. INSTALL FRONT BUMPER COVER
92. INSTALL ENGINE UNDER COVER LH
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for bolt
5.0 Nm (51 kgf-cm, 44 inch lbs.) for nut
93. INSTALL ENGINE UNDER COVER RH
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for bolt
5.0 Nm (51 kgf-cm, 44 inch lbs.) for nut
94. ADD ENGINE OIL
95. ADD ENGINE COOLANT
96. CHECK FOR ENGINE OIL LEAKS
97. CHECK FOR ENGINE COOLANT LEAKS
98. CHECK FOR FUEL LEAKS
99. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
100. CHECK IDLE SPEED AND IGNITION TIMING
101. INSPECT CO/HC
102. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)