Partial Engine Assembly Replacement
REPLACEMENT1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. DRAIN COOLANT
6. DRAIN MANUAL TRANSAXLE OIL
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
7. REMOVE CYLINDER HEAD COVER NO.2
a) Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.
8. REMOVE BATTERY
9. REMOVE BATTERY CARRIER
a) Remove the 4 bolts and battery carrier.
10. SEPARATE ACCELERATOR CONTROL CABLE ASSEMBLY
11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
a) Disconnect the VSV connector.
b) Disconnect the wire harness clamp.
c) Disconnect the vacuum hose.
d) Remove the 3 bolts and air cleaner case.
14. SEPARATE CRUISE CONTROL ACTUATOR ASSEMBLY (W/ CRUISE CONTROL)
a) Disconnect the actuator connector.
b) Remove the 2 bolts, then separate the actuator from the body.
15. DISCONNECT UNION TO CONNECTOR TUBE HOSE
a) Disconnect the union to check valve hose from the brake booster.
16. REMOVE EFI FUEL PIPE CLAMP
17. DISCONNECT FUEL TUBE SUB-ASSEMBLY
18. DISCONNECT HEATER INLET WATER HOSE
a) Disconnect the heater inlet water hose from the air conditioner tube.
19. DISCONNECT HEATER OUTLET WATER HOSE
a) Disconnect the heater outlet water hose from the air conditioner tube.
20. DISCONNECT RADIATOR HOSE INLET
21. DISCONNECT RADIATOR HOSE OUTLET
22. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY
23. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
24. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
25. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
26. DISCONNECT ENGINE WIRE
a) Remove the engine room relay block cover.
b) Disconnect the 3 connectors.
c) Disconnect the 2 wire harness clamps.
d) Disconnect the 2 ground cables from the vehicle.
e) Disconnect the 2 ECM connectors.
f) Disconnect the 3 cowl wire connectors from the connectors on the bracket.
g) Pull the engine wire out of the cabin.
27. REMOVE WIRE HARNESS PROTECTOR
28. SEPARATE SUCTION HOSE SUB-ASSEMBLY
29. REMOVE AIR SWITCHING VALVE ASSEMBLY
30. REMOVE FAN AND GENERATOR V BELT
31. REMOVE GENERATOR BRACKET NO. 1
32. REMOVE GENERATOR ASSEMBLY
33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT: Hang up the hoses instead of detaching.
34. SEPARATE RETURN TUBE SUB-ASSEMBLY
a) Remove the 2 clamp bolts, then separate the return tube.
35. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY
a) Remove the 2 bolts and oil reservoir.
36. REMOVE EXHAUST PIPE ASSEMBLY FRONT
37. SEPARATE STEERING INTERMEDIATE SHAFT
a) Place matchmarks on the sliding yoke and steering intermediate shaft.
b) Loosen the bolt A and remove the bolt B. then disconnect the steering intermediate shaft.
38. REMOVE FRONT AXLE HUB LH NUT
SST 09930-00010
39. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT: Perform the same procedure as above on the opposite side.
40. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
41. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
42. SEPARATE SPEED SENSOR FRONT LH
43. SEPARATE SPEED SENSOR FRONT RH
HINT: Perform the same procedure as above on the opposite side.
44. SEPARATE TIE ROD END SUB-ASSEMBLY LH
SST 09628-62011
45. SEPARATE TIE ROD END SUB-ASSEMBLY RH
SST 09628-62011
HINT: Perform the same procedure as above on the opposite side.
46. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
47. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT: Perform the same procedure as above on the opposite side.
48. SEPARATE FRONT AXLE ASSEMBLY LH
49. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
50. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a) Set the engine lifter.
b) Remove the 5 bolts and 2 nuts, then remove the engine mounting insulator RH.
c) Remove the through bolt and nut, then detach the engine mounting insulator LH from the vehicle.
d) Remove the 6 bolts as shown in the illustration.
e) Carefully remove the engine assembly from the vehicle.
f) Install the 2 engine hangers as shown in the illustration.
Parts No.:
12281-88600 for No. 1 engine hanger
12282-88600 for No. 2 engine hanger
91512-61020 for bolt
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
HINT: Be sure to install the engine hanger (12281-88600) onto the front side of the engine, and the engine hanger (12282-88600) onto the rear side.
g) Using a chain block and engine sling device, hang the engine 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.
b) Remove the through bolt, then detach the engine mounting insulator RR from the suspension crossmember.
c) Separate the engine and transaxle assembly from the front suspension crossmember with center member.
52. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
53. REMOVE STARTER ASSEMBLY
54. REMOVE MANUAL TRANSAXLE ASSEMBLY
55. REMOVE CLUTCH COVER ASSEMBLY
56. REMOVE CLUTCH DISC ASSEMBLY
57. REMOVE FLYWHEEL SUB-ASSEMBLY
a) Hold the crankshaft with SST, then remove the 8 bolts and flywheel.
SST 09213-70011 (09213-70020), 09330-00021
58. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a) Remove the bolt and nut, then remove the V-ribbed belt tensioner.
59. REMOVE MANIFOLD STAY
60. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
61. REMOVE EXHAUST MANIFOLD
62. REMOVE IGNITION COIL ASSEMBLY
63. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
64. REMOVE OIL LEVEL GAGE GUIDE
65. REMOVE SURGE TANK STAY NO. 1
a) Remove the 2 bolts and nut, then remove the surge tank stay.
66. REMOVE INTAKE MANIFOLD
a) Remove the 4 bolts and 2 nuts, then remove the intake manifold and gasket.
67. REMOVE WATER INLET
68. REMOVE THERMOSTAT
69. REMOVE VENTILATION NO. 1 TUBE
a) Remove the 2 nuts, then separate the ventilation No. 1 tube from the cylinder head cover.
b) Remove the 3 nuts, then remove the ventilation case No. 1 from the cylinder block.
c) Remove the 2 gaskets.
70. REMOVE WATER BY-PASS PIPE NO. 1
a) Remove the 2 bolts and 2 nuts, then remove the water by-pass pipe.
b) Remove the gasket.
71. REMOVE CRANKSHAFT POSITION SENSOR
72. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a) Using a 24 mm deep socket wrench, remove the oil pressure switch.
73. REMOVE KNOCK SENSOR
a) Remove the nut and knock sensor.
74. REMOVE CAMSHAFT POSITION SENSOR
75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a) Using SST, remove the engine coolant temperature sensor.
SST 09817-33190
76. REPLACE PARTIAL ENGINE ASSEMBLY
77. 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: 20 Nm (208 kgf-cm, 15 ft. lbs.)
78. INSTALL CAMSHAFT POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
79. I NSTALL KNOCK SENSOR
a) Install the nut and knock sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
80. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a) Clean the threads of the oil pressure switch.
b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
81. INSTALL CRANKSHAFT POSITION SENSOR
a) Install the crankshaft position sensor and cord wiring clamp.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
82. INSTALL WATER BY-PASS PIPE NO. 1
a) Install a new gasket and the water by-pass pipe with the 2 bolts and 2 nuts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for nut
8.5 Nm (87 kgf-cm, 75 inch lbs.) for M6 bolt
21 Nm (214 kgf-cm, 15 ft. lbs.) for M8 bolt
83. INSTALL VENTILATION NO. 1 TUBE
a) Install a new gasket and the ventilation case No. 1 with the 3 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b) Install a new gasket and the ventilation No. 1 tube with the 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
84. INSTALL THERMOSTAT
85. I NSTALL WATER IN LET
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
86. INSTALL INTAKE MANIFOLD
a) Install a new gasket and the intake manifold with the 4 bolts and 2 nuts.
Torque:
34 Nm (347 kgf-cm, 25 ft. lbs.) for bolt A and nut A
46 Nm (469 kgf-cm, 34 ft. lbs.) for bolt B
87. INSTALL SURGE TANK STAY NO. 1
a) Install the surge tank stay with the 2 bolts and nut.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
88. INSTALL OIL LEVEL GAGE GUIDE
a) Apply a light coat of engine oil to a new O-ring, then install it onto the oil level gage guide.
b) Install the oil level gage guide with the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
89. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
90. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
91. INSTALL EXHAUST MANIFOLD
92. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
93. INSTALL MANIFOLD STAY
94. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.) for nut
100 Nm (1,020 kgf-cm, 74 ft. lbs.) for bolt
95. INSTALL FLYWHEEL SUB-ASSEMBLY
a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
b) Clean the 8 bolts and their holes.
c) Apply adhesive to each bolt.
Adhesive: Part No. 09330-00070, THREE BOND or equivalent
d) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
e) Mark each bolt with paint as shown in the illustration.
f) Retighten each bolt 90°.
g) Check that the paint mark on each bolt is at a 90° angle to its original position.
96. INSTALL CLUTCH DISC ASSEMBLY
SST 09301-00210
97. INSTALL CLUTCH COVER ASSEMBLY
SST 09301-00210
98. INSTALL MANUAL TRANSAXLE ASSEMBLY
99. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
100. INSTALL STARTER ASSEMBLY
101. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a) Attach the engine and transaxle assembly to the suspension crossmember with center member.
b) Install the rear engine mounting bracket and mounting insulator with the bolt.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)
c) Install the front engine mounting bracket and mounting insulator with the bolt.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
102. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a) Set the engine assembly with transaxle on the engine lifter.
b) Install the engine assembly onto the vehicle.
c) Temporarily install the suspension crossmember with 6 bolts.
d) Install the engine mounting insulator LH.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
e) Install the engine mounting insulator RH.
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 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 bolt A first, then bolt B.
j) Insert SST into the positioning holes on the right-handle crossmember and the right-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
k) Insert SST into the positioning holes on the left-handle crossmember and the 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
1) Tighten the 2 bolts as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
NOTICE: After installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
103. INSTALL FRONT AXLE ASSEMBLY LH
104. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
105. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
106. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT: Perform the same procedure as above on the opposite side.
107. INSTALL TIE ROD END SUB-ASSEMBLY LH
108. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
109. INSTALL SPEED SENSOR FRONT LH
110. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure as above on the opposite side.
111. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
112. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
113. INSTALL FRONT AXLE HUB LH NUT
114. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure as above on the opposite side.
115. INSTALL STEERING INTERMEDIATE SHAFT
a) Align the matchmarks on the sliding yoke and steering intermediate shaft as shown.
b) Install the bolt B and tighten the bolt A to specified torque.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
116. INSTALL EXHAUST PIPE ASSEMBLY FRONT
117. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
118. 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
119. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
120. INSTALL GENERATOR ASSEMBLY
121. INSTALL GENERATOR BRACKET NO. 1
122. INSTALL AIR SWITCHING VALVE ASSEMBLY
123. INSTALL SUCTION HOSE SUB-ASSEMBLY
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)
124. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
125. CONNECT FUEL TUBE SUB-ASSEMBLY
126. INSTALL EFI FUEL PIPE CLAMP
127. INSTALL CRUISE CONTROL ACTUATOR ASSEMBLY (W/CRUISE CONTROL)
a) Install the actuator with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
b) Connect the actuator connector.
128. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
129. INSTALL BATTERY CARRIER
a) Install the battery carrier with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
130. 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
131. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
132. ADD MANUAL TRANSAXLE OIL
133. ADD ENGINE OIL
134. ADD COOLANT
135. CHECK FOR ENGINE OIL LEAKAGE
136. CHECK FOR ENGINE COOLANT LEAKAGE
137. CHECK FOR FUEL LEAKAGE
138. CHECK FOR EXHAUST GAS LEAKAGE
139. INSPECT IGNITION TIMING
SST 09843-18040
140. INSPECT ENGINE IDLING SPEED
141. INSPECT CO/HC
142. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
143. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
144. CHECK ABS SPEED SENSOR SIGNAL