Operation CHARM: Car repair manuals for everyone.

Removal












1. Remove hood insulator.
2. Disconnect hood supports from hood.
3. Remove hood.
NOTE: Be careful not to damage the body or glass with the hood end.
4. Remove engine under cover.
5. Drain engine coolant.
6. Drain engine oil.
7. Drain fuel from fuel tank.
8. Disconnect the accelerator cable and cruise control actuator cable.
9. Remove air cleaner duct.
10. Remove air cleaner, Mass Air Flow (MAF) meter and intake air connector pipe assembly
11. Remove drive belt.
12. Remove radiator assembly, refer to Cooling System.
Cooling System
13. Disconnect wires and connectors as follows:
(a) Disconnect the igniter connector.



(b) Disconnect the ignition coil connector.
(c) Disconnect the wire harness from the wire clamp and coolant reservoir.
(d) Disconnect the generator connector.
(e) Remove the rubber cap and nut, and disconnect the generator wire.
(f) Remove the bolt, and disconnect the ground strap from the LH engine mounting bracket.



(g) Remove the rubber cap and nut, and disconnect the starter wire.

14. Disconnect fuel hoses as follows:
(a) Remove the union bolt and 2 gaskets, disconnect the fuel inlet hose, and suspend the hose union end upward.

NOTE:
- Put a suitable container or shop rag under the fuel pipe support.
- Slowly loosen the union bolt.




(b) Disconnect the fuel return hose from the intake manifold stay and No.2 fuel pipe. Plug the hose end.

15. Disconnect Power Steering (PS) pump without disconnecting hoses as follows:
(a) Disconnect these hoses:



- PS air hose from No.4 timing belt cover
- PS air hose from air intake chamber
(b) Remove the 2 bolts and pump rear stay.



(c) Remove the 3 bolts, plate washer and pump front bracket.



(d) Remove the 2 bolts and pump bracket, and disconnect the vane pump from the engine.
NOTE: Put aside the vane pump, and suspend it securely.

16. Disconnect A/C compressor without disconnecting hoses as follows:



(a) Loosen the 2 mounting bolts.
(b) Remove the nut.



(c) Using a torx socket (E10), remove the stud bolt.
(d) Disconnect the compressor connector.



(e) Remove the 2 mounting bolts and nut, and disconnect the compressor from the engine.
NOTE: Put aside the compressor, and suspend it securely.

17. Disconnect brake booster vacuum hose.
18. Disconnect EVAP hose.
19. Disconnect heater water hoses.
20. Disconnect heater water valve and engine wire from cowl panel as follows:
(a) Disconnect the water valve control cable.
(b) Remove the 2 nuts, and disconnect the ground strap and engine wire protector.



(c) Remove the 2 bolts holding the heater water valve to the cowl panel.
(d) Remove the cruise control actuator cover.
(e) Disconnect the engine wire clamp from the bracket.
(f) Remove the 2 bolts holding the engine wire retainer to the cowl panel.

21. Disconnect engine wire from cabin as follows:
(a) Remove the scuff plate.
- Tape a screwdriver tip before use.
- Using the screwdriver, pry out the front side of the clip.
- Using a clip remover, remove the scuff plate.
(b) Remove the instrument panel under cover.
- Tape a screwdriver tip before use.
- Using the screwdriver, pry out the under cover, and disconnect it from the instrument panel.
- Disconnect the step light from the under cover.
(c) Remove the air heater guide.
(d) Take out the front side of the floor carpet.



(e) Remove the bolt, 2 nuts and Engine Control Module (ECM) protector.
(f) Remove the nut, and disconnect the ECM from the floor panel.
(g) Disconnect the connector from the ECM.
(h) Disconnect the connector from the cowl wire connector.
(i) Pull out the engine wire from the cabin.

22. Disconnect heated oxygen sensor from front exhaust pipe as follows:



(a) Disconnect the wire grommet from the floor.
(b) Remove the 2 bolts and sensor cover.
(c) Disconnect the oxygen sensor from the exhaust pipe.

23. Remove exhaust pipe assembly as follows:



(a) Remove the 2 bolts and nuts holding the front exhaust pipe to the No.2 front exhaust pipe.
(b) Remove the 2 bolts and pipe support bracket.
(c) Remove the gasket and disconnect the front exhaust pipe.



(d) Disconnect the 2 hooks of the tailpipe from the rings.
(e) Disconnect the 2 rings on the exhaust pipe from the exhaust pipe brackets, and remove the exhaust pipe.




24. Remove 4 nuts for No.2 front exhaust pipe, then the exhaust pipe and 2 gaskets.




25. Remove 6 bolts from exhaust pipe heat insulator, then the insulator.




26. Remove the the 4 bolts from rear center floor crossmember brace, then the brace.




27. DIsconnect transmission control rod from the shift lever.
28. Remove propeller shaft.
29. Place a suitable jack under transmission with a wooden block between a jack and the transmission oil pan to prevent damage.







30. Remove the 4 nuts holding the rear support member to the engine rear mounting insulator, then remove the 4 nuts and the member.
31. Remove engine and transmission assembly from vehicle as follows:



(a) Attach the engine hoist chain to the 2 engine hangers.
(b) Remove the 2 hole plugs.



(c) Remove the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.



(d) Lift the engine out of the vehicle slowly and carefully.
NOTE: Remove carefully without damaging the A/C compressor or cooling fan.
(e) Make sure the engine is clear of all wiring, hoses and cables.
(f) Place the engine and transmission assembly onto the stand.