Removal and Replacement
Removal
CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Inspection the timing belt before removing the cylinder head.
- Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Disconnect the terminals (A) and remove the battery (B).
2. Remove the engine cover.
3. Remove the air duct (A).
Tightening torque :
7.8 - 10.8N.m (0.8 - 1.1kgf.m, 5.8 - 8.0lb-ft)
4. Remove the radiator cap to speed daring.
5. Loosen the radiator drain plug (A) and drain engine coolant.
6. Remove the air cleaner assembly.
(1) Disconnect the power train control module (PCM) connector (A).
(2) Disconnect the intake hose (B).
(3) Remove the air cleaner assembly (C).
Tightening torque :
Hose clamp :
2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 2.6lb-ft)
Mounting bolt :
7.8 - 10.8N.m (0.8 - 1.1kgf.m, 5.8 - 8.0lb-ft)
7. Remove the battery tray (A) and the front connector (B).
Tightening torque :
8.8 - 13.7N.m (0.9 - 1.4kgf.m, 6.5 - 10.1lb-ft)
8. Remove the upper radiator hose (A) and lower radiator hose (B).
9. Disconnect the auto transaxle fluid (ATF) hose (A).
10. Remove the heater hose (A).
11. Remove the junction box cover.
12. Disconnect the terminals(A) from the fuse box.
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
13. After removing the mounting bolts, remove the relay and fuse assembly(A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
14. Remove the connector wiring(A) and the engine wiring(B).
15. Remove the engine control side ground(A) and, the transaxle control side one(B).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
16. Remove the fuel inlet from delivery pipe (A) and brake booster vacuum hose (B).
17. Disconnect the accelerator cable (C) and the auto-cruise cable(D) from the cylinder head cover.
18. Remove the transaxle wire and control cable. .
19. Remove the high & low pressure pipe. .
20. Remove the steering u-joint mounting bolt(A).
21. Install the SST (09200-38001, 09200-1C000), the engine support fixture and the adapter, on the engine and transaxle assembly.
22. Remove the engine mounting bracket (A) by removing the bolts(B, C) and nuts(D) and ground line (F).
Tightening torque :
Bolt (B) :
63.7 - 83.3N.m (6.5 - 8.5kgf.m, 47.0 - 61.5lb-ft)
Bolt (C), Nuts (D) :
49.0 - 63.7N.m (5.0 - 6.5kgf.m, 36.2 - 47.0lb-ft)
Bolt (E) :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
23. Remove the transaxle mounting bracket (A) and the ground line (B).
Tightening torque :
A : 88.2 - 107.8N.m (9.0 - 11.0kgf.m, 65.1 - 79.5lb-ft)
B : 9.8 - 14.7N.m (1.0 - 1.5kgf.m, 7.2 - 10.8lb-ft)
24. Remove the front tires.
25. Disconnect the stabilizer bar link and remove the mounting bolts from the lower arm and the front axles.
26. Remove the front muffler (A) and disconnect the rear oxygen sensor connector(B).
27. Remove the sub frame bolts (A).
Tightening torque :
49.0 - 63.7N.m (5.0 - 6.5kgf.m, 36.2 - 47.0lb-ft)
28. Remove the engine support fixture and the adapter.
29. Jack up the vehicle.
Installation
Installation is in the reverse order of removal.
Perform the following :
- Adjust shift cable.
- Adjust throttle cable.
- Refill engine with engine oil.
- Refill transaxle with fluid.
- Refill radiator with engine coolant.
- Bleed air from the cooling system with the heater valve open.
- Clean battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
- Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressureizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.