Removal and Installation
PARTIAL ENGINE ASSEMBLY (1ZZ-FE)
COMPONENTS
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE CYLINDER HEAD COVER NO.2
7. DRAIN ENGINE COOLANT
8. DISCONNECT RADIATOR HOSE INLET
9. DISCONNECT RADIATOR HOSE OUTLET
10. DISCONNECT OIL COOLER INLET HOSE NO.1 (AUTOMATIC TRANSAXLE)
11. DISCONNECT OIL COOLER OUTLET HOSE NO.1 (AUTOMATIC TRANSAXLE)
12. REMOVE RADIATOR ASSEMBLY (W/ AIR CONDITIONING)
13. REMOVE BATTERY
14. REMOVE BATTERY TRAY
15. REMOVE BATTERY CARRIER
a. Remove the 4 bolts, then remove the battery carrier.
16. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
17. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
a. Disconnect the clamp of the engine wire.
b. Remove the 3 bolts from the air cleaner case.
c. Disconnect the air cleaner case from the air cleaner inlet No.1.
18. DISCONNECT FUEL TUBE SUB-ASSEMBLY
SST 09268-21010
19. DISCONNECT UNION TO CHECK VALVE HOSE
20. DISCONNECT HEATER INLET WATER HOSE
a. Disconnect the heater inlet water hose from the air conditioner tube.
21. DISCONNECT HEATER OUTLET WATER HOSE
a. Disconnect the heater outlet water hose from the air conditioner tube.
22. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (MANUAL TRANSAXLE)
23. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (AUTOMATIC TRANSAXLE)
24. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (MANUAL TRANSAXLE)
25. REMOVE FAN AND GENERATOR V BELT
26. REMOVE GENERATOR ASSEMBLY
27. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT: Secure the compressor and hoses off to the side instead of discharging the A/C system.
28. SEPARATE RETURN TUBE SUB-ASSEMBLY
a. Separate the vane pump oil reservoir from the oil reservoir bracket.
b. Remove the 2 bolts, then separate the return tube.
29. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
30. REMOVE FRONT DOOR SCUFF PLATE RH
31. REMOVE COWL SIDE TRIM BOARD RH
32. 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. Disconnect the 3 connectors.
e. Disconnect the engine wire harness by pulling it upward.
f. Remove the clamp of the engine wire.
g. Remove the bolt, then disconnect the ground terminal.
33. REMOVE FLOOR PANEL BRACE FRONT
34. REMOVE EXHAUST PIPE ASSEMBLY FRONT
35. REMOVE COLUMN HOLE COVER SILENCER SHEET
36. SEPARATE STEERING INTERMEDIATE SHAFT
37. REMOVE FRONT AXLE HUB LH NUT
SST 09930-00010
38. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT: Perform the same procedure as above on the opposite side.
39. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
40. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
41. SEPARATE SPEED SENSOR FRONT LH (W/ ABS)
42. SEPARATE SPEED SENSOR FRONT RH (W/ ABS)
HINT: Perform the same procedure as above on the opposite side.
43. SEPARATE TIE ROD END SUB-ASSEMBLY LH
SST 09628-62011
44. SEPARATE TIE ROD END SUB-ASSEMBLY RH
SST 09628-62011
HINT: Perform the same procedure as above on the opposite side.
45. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
46. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT: Perform the same procedure as above on the opposite side.
47. SEPARATE FRONT AXLE ASSEMBLY LH
48. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
49. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH.
c. Remove the through bolt and nut, then separate the engine mounting insulator LH.
d. Remove the 6 bolts as shown in the illustration.
e. Carefully remove the engine with transaxle from the engine compartment.
f. Install the engine hanger (12281-22021) with the bolt (91512-131016 or 90080-10161).
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
g. Install the engine hanger (12281-15050) with the bolt (91512-131016 or 90080-10161).
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
HINT: Securely install the front engine hanger (12281-22021) and the rear engine hanger (12281-15050) onto the engine assembly.
h. Attach the engine sling and hang the engine with the chain block.
50. SEPARATE VANE PUMP ASSEMBLY
51. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Remove the through bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR.
b. Remove the through bolt, then separate the 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.
52. REMOVE STARTER ASSEMBLY
53. REMOVE MANUAL TRANSAXLE ASSEMBLY (MANUAL TRANSAXLE)
54. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (AUTOMATIC TRANSAXLE)
55. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSAXLE)
56. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSAXLE)
57. REMOVE FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSAXLE)
SST 09960-10010 (09962-01000, 09963-01000)
58. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSAXLE)
SST 09960-10010 (09962-01000, 09963-01000)
59. REMOVE IGNITION COIL ASSEMBLY
60. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
61. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
62. REMOVE INTAKE MANIFOLD
63. REMOVE OIL LEVEL GAGE GUIDE
a. Disconnect the crankshaft position sensor clamp.
b. Remove the bolt, then remove the oil level gage guide.
64. REMOVE WATER BY-PASS PIPE NO.1
a. Disconnect the knock sensor clamp.
b. Remove the 2 bolts and 2 nuts, then remove the water by-pass pipe No.1.
c. Remove the gasket from the cylinder block.
65. REMOVE WATER INLET
66. REMOVE THERMOSTAT
67. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
68. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the bolt, then remove the camshaft position sensor.
69. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the 2 bolts, then remove the crankshaft position sensor.
70. REMOVE KNOCK SENSOR
a. Remove the nut, then remove the knock sensor.
71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
72. REMOVE MANIFOLD STAY
a. Remove the 3 bolts and manifold stay.
73. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Disconnect the air fuel ratio sensor connector.
b. Remove the 4 bolts, then remove the exhaust manifold heat insulator.
74. REMOVE EXHAUST MANIFOLD
a. Remove the 5 nuts, then remove the exhaust manifold.
b. Remove the gasket from the cylinder head.
75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using SST, remove the engine coolant temperature sensor.
SST 09817-33190
76. REMOVE RADIO SETTING CONDENSER
a. Remove the bolt, then remove the condenser.
77. REMOVE WATER BY-PASS HOSE NO.2
78. REMOVE RADIATOR HOSE INLET
79. REMOVE HEATER INLET WATER HOSE
80. REPLACE PARTIAL ENGINE ASSEMBLY
81. INSTALL HEATER INLET WATER HOSE
82. INSTALL RADIATOR HOSE INLET
83. INSTALL WATER BY-PASS HOSE NO.2
84. INSTALL RADIO SETTING CONDENSER
a. Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
85. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket onto the engine coolant temperature sensor.
b. Using SST, install the engine coolant temperature sensor.
SST 09817-33190
Torque: 19.6 Nm (200 kgf-cm, 14 ft. lbs.)
86. INSTALL EXHAUST MANIFOLD
a. Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
87. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the air fuel ratio sensor connector.
88. INSTALL MANIFOLD STAY
a. Install the manifold stay with 3 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
89. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
90. INSTALL KNOCK SENSOR
a. Install the knock sensor with the nut.
Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.)
91. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
92. INSTALL CAMSHAFT POSITION SENSOR
a. Install the camshaft position sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
93. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
94. INSTALL THERMOSTAT
95. INSTALL WATER INLET
96. INSTALL WATER BY-PASS PIPE NO.1
a. Install a new gasket and the water by-pass pipe No.1 with the 2 nuts and 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Connect the knock sensor clamp.
97. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to a new O-ring and install it onto the oil level gage guide.
b. Install the oil level gage guide with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
c. Connect the crankshaft position sensor clamp.
98. INSTALL INTAKE MANIFOLD
99. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
100. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
101. INSTALL IGNITION COIL ASSEMBLY
102. INSTALL FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSAXLE)
SST 09960-10010 (09962-01000, 09963-01000)
103. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSAXLE)
SST 09960-10010 (09962-01000, 09963-01000)
104. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSAXLE) SST 09301-00210
105. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSAXLE)
106. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (AUTOMATIC TRANSAXLE)
107. INSTALL MANUAL TRANSAXLE ASSEMBLY (MANUAL TRANSAXLE)
108. INSTALL STARTER ASSEMBLY
109. INSTALL FRONT SUSPENSION CROSSMEMBER W/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 engine mounting insulator RR, into the engine mounting bracket RR.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)
c. Install the bolt, which is used to secure the engine mounting insulator FR, into the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
110. INSTALL VANE PUMP ASSEMBLY
111. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine with transaxle onto the vehicle.
c. Temporarily install the suspension crossmember with the 6 bolts.
d. Install the engine mounting insulator LH with the through bolt and nut.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
e. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
f. Insert SST into the positioning holes on the right handle crossmember and on the right-handle of the vehicle. SST 09670-00010
g. Temporarily tighten the bolt A first, then bolt B.
h. Insert SST into the positioning holes on the left handle crossmember and on the left-handle of the vehicle.
SST 09670-00010
i. Temporarily tighten the bolt A first, then bolt B.
j. Insert SST into the positioning holes on the right-handle crossmember and right-handle of the vehicle, then tight en the bolts to the specified torque.
k. Insert SST into the positioning holes on the right-handle crossmember and left-handle of the vehicle, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
157 Nm (1,601 kgf-cm, 116 ft. lbs.) for bolt A
113 Nm (1,152 kgf-cm, 83 ft. lbs.) for bolt B
l. Tighten the 2 bolts as shown in the illustration.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
NOTICE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
112. INSTALL FRONT AXLE ASSEMBLY LH
113. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
114. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
115. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT: Perform the same procedure as above on the opposite side.
116. INSTALL TIE ROD END SUB-ASSEMBLY LH
117. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
118. INSTALL SPEED SENSOR FRONT LH (W/ ABS)
119. INSTALL SPEED SENSOR FRONT RH (W/ ABS)
HINT: Perform the same procedure as above on the opposite side.
120. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
121. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
122. INSTALL FRONT AXLE HUB LH NUT
123. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure as above on the opposite side.
124. INSTALL STEERING INTERMEDIATE SHAFT
125. INSTALL COLUMN HOLE COVER SILENCER SHEET
126. INSTALL EXHAUST PIPE ASSEMBLY FRONT
127. INSTALL FLOOR PANEL BRACE FRONT
128. CONNECT ENGINE WIRE
129. INSTALL COWL SIDE TRIM BOARD RH
130. INSTALL FRONT DOOR SCUFF PLATE RH
131. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
132. INSTALL RETURN TUBE SUB-ASSEMBLY
a. Install the return tube with the 2 bolts.
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for bolt A
7.8 Nm (80 kgf-cm, 69 inch lbs.) for bolt B
b. Install the vane pump oil reservoir onto the oil reservoir bracket.
133. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
134. INSTALL GENERATOR ASSEMBLY
135. INSTALL FAN AND GENERATOR V BELT
136. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (MANUAL TRANSAXLE)
137. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (AUTOMATIC TRANSAXLE)
138. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (MANUAL TRANSAXLE)
139. CONNECT HEATER OUTLET WATER HOSE
140. CONNECT HEATER INLET WATER HOSE
141. CONNECT UNION TO CHECK VALVE HOSE
142. CONNECT FUEL TUBE SUB-ASSEMBLY
143. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
a. Connect the air cleaner case to the air cleaner inlet No.1.
b. Install the air cleaner case with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
c. Connect the clamp of the engine wire.
144. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
145. INSTALL BATTERY CARRIER
a. Install the battery carrier and bracket with the 4 bolts.
Torque: 12.8 Nm (131 kgf-cm, 9 ft. lbs.)
146. INSTALL BATTERY TRAY
147. INSTALL BATTERY
Torque:
5.0 Nm (51 kgf-cm, 44 inch lbs.) for bolt
3.5 Nm (36 kgf-cm, 31 inch lbs.) for nut
5.4 Nm (55 kgf-cm, 48 inch lbs.) for terminal
148. INSTALL RADIATOR ASSEMBLY (W/ AIR CONDITIONING)
149. CONNECT OIL COOLER OUTLET HOSE NO.1 (AUTOMATIC TRANSAXLE)
150. CONNECT OIL COOLER INLET HOSE NO.1 (AUTOMATIC TRANSAXLE)
151. CONNECT RADIATOR HOSE OUTLET
152. CONNECT RADIATOR HOSE INLET
153. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
154. ADD ENGINE COOLANT
155. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
156. CHECK FOR ENGINE COOLANT LEAKAGE
157. CHECK FOR ENGINE OIL LEAKAGE
158. CHECK FOR FUEL LEAKAGE
159. CHECK FOR EXHAUST GAS LEAKAGE
160. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
161. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)
162. INSPECT IGNITION TIMING
SST 09843-18040
163. INSPECT ENGINE IDLING SPEED
164. INSPECT CO/HC
165. INSTALL CYLINDER HEAD COVER NO.2
166. INSTALL ENGINE UNDER COVER LH
167. INSTALL ENGINE UNDER COVER RH