Engine Removal and Installation

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE BATTERY
a) Loosen the 2 nuts and remove the battery clamp.
4. REMOVE BATTERY TRAY
5. REMOVE FRONT WHEEL
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE FRONT FENDER APRON SEAL RH
9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
10. DRAIN ENGINE COOLANT
11. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)
12. DRAIN TRANSAXLE OIL (for Manual Transaxle)
13. DISCONNECT RADIATOR HOSE INLET
14. DISCONNECT RADIATOR HOSE OUTLET
15. DISCONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)
16. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)
17. REMOVE RADIATOR ASSEMBLY

18. REMOVE AIR CLEANER ASSEMBLY
a) Remove the air cleaner cap and element.
b) Remove the clamp of the engine wire.
c) Remove the 3 bolts from the air cleaner case.
d) Disconnect the air cleaner case from the No. 1 air cleaner inlet.

19. REMOVE BATTERY CARRIER
a) Disconnect the clamp of the engine wire.
b) Remove the 4 bolts and battery carrier.
20. DISCONNECT FUEL MAIN TUBE

21. DISCONNECT UNION TO CONNECTOR TUBE HOSE
a) Disconnect the union to connector tube hose from the booster vacuum tube.

22. DISCONNECT HEATER WATER INLET HOSE
a) Disconnect the heater water inlet hose from the booster vacuum tube.

23. DISCONNECT HEATER WATER OUTLET HOSE
a) Disconnect the heater water outlet hose from the air conditioner tube.
24. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
25. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
26. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
27. REMOVE FAN AND GENERATOR V BELT
28. REMOVE GENERATOR ASSEMBLY
29. REMOVE COOLER COMPRESSOR ASSEMBLY

HINT: Disconnect the compressor together with the low pressure and high-pressure hoses, then secure it to the vehicle side using rope.

30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

31. DISCONNECT ENGINE WIRE
a) Disconnect the engine wire from the ECM and junction block.
b) Pull out the engine wire.
c) Remove the engine room relay block cover.
d) Remove the 2 claws and 2 connectors, and push the engine wire harness up.

e) Remove the 2 clamps of the engine wire.

f) Remove the nut from the battery positive (+) terminal to disconnect the engine wire.

g) Remove the bolt and ground cable.
32. REMOVE FRONT EXHAUST PIPE ASSEMBLY
33. REMOVE COLUMN HOLE COVER SILENCER SHEET
34. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
35. REMOVE FRONT AXLE HUB NUT
36. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
38. DISCONNECT FRONT SPEED SENSOR LH
39. DISCONNECT FRONT SPEED SENSOR RH
40. SEPARATE TIE ROD END LH SUB-ASSEMBLY
41. REMOVE TIE ROD END RH SUB-ASSEMBLY
42. SEPARATE FRONT NO. 1 SUSPENSION ARM SUBASSEMBLY LOWER LH
43. SEPARATE FRONT NO. 1 SUSPENSION ARM SUBASSEMBLY LOWER RH
44. REMOVE FRONT AXLE HUB LH SUB-ASSEMBLY
45. REMOVE FRONT AXLE HUB RH SUB-ASSEMBLY

46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a) Disconnect the No. 1 pump hose.

b) Disconnect the return tube.
c) Set the engine lifter.

d) Remove the 2 bolts, 2 nuts and engine mounting insulator RH.

e) Remove the through bolt, nut and engine mounting insulator LH.

f) Remove the 8 bolts and front suspension member brace rear RH and LH.

g) Remove the 2 bolts and 2 nuts shown in the illustration.
h) Carefully remove the engine with transaxle from the vehicle.

i) Install the No. 1 and No. 2 engine hangers with the bolts as shown in the illustration.
Parts No.

Parts No.:

Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
j) Attach the sling device and the engine with the chain block.
47. REMOVE VANE PUMP ASSEMBLY

48. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER
a) Remove the through bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.

b) Remove the through bolt and engine mounting insulator RR from the engine mounting bracket RR.
c) Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
49. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
50. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
51. REMOVE STARTER ASSEMBLY
52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
53. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle)

54. REMOVE DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle)
a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

b) Remove the 8 bolts, rear spacer, drive plate and front spacer.
55. REMOVE MANUAL TRANSAXLE ASSEMBLY
56. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)
57. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)

58. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

b) Remove the 8 bolts and flywheel.

59. REMOVE DRIVE SHAFT BEARING BRACKET
a) Remove the 3 bolts and drive shaft bearing bracket.
60. REMOVE OIL DIPSTICK
61. REMOVE OIL DIPSTICK GUIDE
62. REMOVE MANIFOLD STAY
63. REMOVE NO. 2 MANIFOLD STAY
64. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
65. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY
66. REMOVE WATER INLET
67. REMOVE THERMOSTAT

68. REMOVE NO. 1 WATER BY-PASS PIPE
a) Remove the bolt, 2 nuts and water by-pass pipe.
b) Remove the gasket from the cylinder block.
69. REMOVE INTAKE MANIFOLD ASSEMBLY
70. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR
71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
72. REMOVE IGNITION COIL ASSEMBLY
73. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
74. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
75. REMOVE KNOCK SENSOR

76. REMOVE RADIO SETTING CONDENSER
a) Remove the bolt and condenser.
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
78. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
79. REPLACE PARTIAL ENGINE ASSEMBLY

INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

3. INSTALL RADIO SETTING CONDENSER
a) Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
4. INSTALL KNOCK SENSOR
5. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY
6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
7. INSTALL IGNITION COIL ASSEMBLY
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
9. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
10. INSTALL INTAKE MANIFOLD ASSEMBLY

11. INSTALL NO. 1 WATER BY-PASS PIPE
a) Install a new gasket and the water by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
12. INSTALL THERMOSTAT
13. INSTALL WATER INLET
14. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY
15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
16. INSTALL NO. 2 MANIFOLD STAY
17. INSTALL MANIFOLD STAY
18. INSTALL OIL DIPSTICK GUIDE
19. INSTALL OIL DIPSTICK

20. INSTALL DRIVE SHAFT BEARING BRACKET
a) Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
21. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
a) Clean the 8 bolts and 8 bolt holes.
b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent

c) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

d) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 130 Nm (1,326 kgf-cm, 96 ft. lbs.)
22. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
23. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
24. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
25. INSTALL DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle)
a) Clean the 8 bolts and 8 bolt holes.
b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent

c) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
d) Install the front spacer, drive plate and rear spacer onto the crankshaft.

e) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
26. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
27. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
28. INSTALL STARTER ASSEMBLY
29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER
a) Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
b) Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

c) Install the bolt which is used to secure the front engine mounting bracket.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
32. INSTALL VANE PUMP ASSEMBLY
33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a) Set the engine assembly with transaxle on the engine lifter.

b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.

c) Install the engine mounting insulator LH with the through bolt and nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

d) Install the engine mounting insulator RH with the 2 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
113 Nm (1,152 kgf-cm, 83 ft. lbs.) for bolt A

e) Tighten the 2 bolts and 2 nuts.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.) for bolt
133 Nm (1,356 kgf-cm, 98 ft. lbs.) for nut

f) Install the front suspension member brace rear RH and LH with the 8 bolts.
Torque: 133 Nm (1,356 kgf-cm, 98 ft. lbs.) for bolt A
80 Nm (816 kgf-cm, 59 ft. lbs.) for bolt B

NOTICE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.

g) Connect the return tube.

h) Connect the oil reservoir to No. 1 pump hose.

i) Remove the No. 1 and No. 2 engine hangers.
34. INSTALL FRONT AXLE HUB SUB-ASSEMBLY
35. INSTALL FRONT AXLE HUB HOLE SNAP RING
36. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH
37. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY RH
38. INSTALL TIE ROD END SUB-ASSEMBLY LH
39. INSTALL TIE ROD END SUB-ASSEMBLY RH
40. INSTALL FRONT SPEED SENSOR LH
41. INSTALL FRONT SPEED SENSOR RH
42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
44. INSTALL FRONT AXLE HUB NUT LH
45. INSTALL FRONT AXLE HUB NUT RH
46. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
47. INSTALL COLUMN HOLE COVER SILENCER SHEET
48. INSTALL FRONT EXHAUST PIPE ASSEMBLY

49. CONNECT ENGINE WIRE
a) Install the ground cable with the bolt.

b) Install the engine wire to the battery positive terminal with the nut.

c) Install the 2 clamps of the engine wire.

d) Install the engine wire harness with the 2 claws.
e) Connect the 2 connectors.
50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
51. INSTALL COOLER COMPRESSOR ASSEMBLY
52. INSTALL GENERATOR ASSEMBLY
53. INSTALL FAN AND GENERATOR V BELT
54. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
55. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

57. CONNECT HEATER WATER OUTLET HOSE
a) Connect the heater outlet hose to the air conditioner tube.

58. CONNECT HEATER WATER INLET HOSE
a) Connect the heater inlet hose to the air conditioner tube.

59. CONNECT UNION TO CONNECTOR TUBE HOSE
a) Connect the union to connector tube to the booster vacuum tube.
60. CONNECT FUEL MAIN TUBE

61. INSTALL BATTERY CARRIER
a) Install the battery carrier with the 4 bolts.
Torque: 12.8 Nm (131 kgf-cm, 9 ft. lbs.)
b) Connect the clamp of the engine wire.

62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
a) Connect the air cleaner case to the No. 1 air cleaner inlet.
b) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
c) Connect the clamp of the engine wire.
63. INSTALL AIR CLEANER FILTER ELEMENT SUBASSEMBLY
64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
65. INSTALL RADIATOR ASSEMBLY
66. CONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)
67. CONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)
68. CONNECT RADIATOR HOSE OUTLET
69. CONNECT RADIATOR HOSE INLET
70. INSTALL BATTERY TRAY
71. INSTALL BATTERY
72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
73. ADD MANUAL TRANSAXLE OIL
74. ADD AUTOMATIC TRANSAXLE FLUID
75. ADD ENGINE COOLANT
76. CHECK FOR FUEL LEAKAGE
77. CHECK FOR ENGINE COOLANT LEAKS
a) Check for the engine coolant leaks.
78. CHECK FOR MANUAL TRANSAXLE OIL LEAKS
79. CHECK FOR AUTOMATIC TRANSAXLE FLUID LEAKS
80. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
81. INSTALL FRONT FENDER APRON SEAL RH
82. INSTALL ENGINE UNDER COVER LH
83. INSTALL ENGINE UNDER COVER RH
84. INSTALL FRONT WHEEL
85. PERFORM INITIALIZATION
a) Perform initialization. Testing and Inspection

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.