Part 1
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. DRAIN COOLANT
6. DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
7. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 3 bolts, the nut and 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 ASSY
11. REMOVE AIR CLEANER CAP SUB-ASSY
12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY
13. REMOVE AIR CLEANER CASE SUB-ASSY
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. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
a. Disconnect the actuator connector.
b. Remove the 2 bolts, and disconnect 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-ASSY
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. DISCONNECT CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
23. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
24. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
25. REMOVE GLOVE COMPARTMENT DOOR ASSY
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 connectors on bracket.
g. Pull out the engine wire from the cabin.
27. REMOVE WIRE HARNESS PROTECTOR
a. Unfasten the 3 clips, then remove the wire harness protector.
b. Disconnect the pressure sensor connector.
28. REMOVE AIR SWITCHING VALVE ASSY
29. DISCONNECT SUCTION HOSE SUB-ASSY
a. Remove the 2 nuts installing the suction hose sub-assy.
b. Disconnect the suction hose sub-assy.
30. REMOVE FAN AND GENERATOR V-BELT
a. Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and put back the drive belt tensioner little by little and fix it quietly.
31. REMOVE GENERATOR BRACKET NO.1
32. REMOVE GENERATOR ASSY
33. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)
HINT: Hung up the hoses instead of detaching.
34. SEPARATE RETURN TUBE SUB-ASSY
a. Remove the 2 clamp bolts, and separate the return tube sub-assy.
35. SEPARATE VANE PUMP OIL RESERVOIR ASSY
a. Remove the 2 bolts and the oil reservoir assy.
36. REMOVE EXHAUST PIPE ASSY FRONT
37. REMOVE 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 on the opposite side.
40. SEPARATE FRONT STABILIZER LINK ASSY LH
41. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
42. SEPARATE SPEED SENSOR FRONT LH
43. SEPARATE SPEED SENSOR FRONT RH
HINT: Perform the same procedure on the opposite side.
44. SEPARATE TIE ROD END SUB-ASSY LH
SST 09628-62011
45. SEPARATE TIE ROD END SUB-ASSY RH
SST 09628-62011
HINT: Perform the same procedure on the opposite side.
46. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
47. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the opposite side.
48. SEPARATE FRONT AXLE ASSY LH
49. SEPARATE FRONT AXLE ASSY RH
HINT: Perform the same procedure on the opposite side.
50. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 5 bolts, 2 nuts and engine mounting insulator RH.
c. Remove the through bolt and nut, 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.:
No. 1 engine hanger 12281-88600
No. 2 engine hanger 12282-88600
Bolt: 91512-61020
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
HINT: Be sure to install engine hanger (12281-88600) to the front side of the engine, and engine hanger (12282-88600) to the rear side.
g. Using the chain block and engine sling device, hang the engine assembly.
51. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Remove the through bolt and a nut, detach the engine mounting insulator FR from the engine mounting bracket.
b. Remove the through bolt, detach the engine mounting insulator RR from the suspension crossmember.
c. Separate the engine and transaxle assembly from the front suspension crossmember w/center member.
52. REMOVE FRONT DRIVE SHAFT ASSY RH
53. REMOVE STARTER ASSY
54. SEPARATE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
55. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE)
56. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE)
57. REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL
a. Fix the crankshaft with SST, then remove the drive plate and ring gear or the flywheel.
SST 09213-70011 (09213-70020), 09330-00021
58. REMOVE V-RIBBED BELT TENSIONER ASSY
a. Remove the bolt and nut, then remove the V-ribbed belt tensioner.
59. REMOVE MANIFOLD STAY
a. Remove the 2 bolts, the nut and exhaust manifold stay.
60. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
61. REMOVE EXHAUST MANIFOLD
a. Remove the 4 bolts, 2 nuts, exhaust manifold and gasket.
62. REMOVE IGNITION COIL ASSY
a. Remove the 3 bolts, the nut and the 4 ignition coils.
63. REMOVE FUEL DELIVERY PIPE SUB-ASSY
64. REMOVE OIL LEVEL GAGE GUIDE
65. REMOVE SURGE TANK STAY NO.1
a. Remove the 2 bolts, the nut and the surge tank stay.
66. REMOVE INTAKE MANIFOLD
a. Remove the 4 bolts, the 2 nuts, the intake manifold and the 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 BYPASS PIPE NO.1
a. Remove the 2 bolts and 2 nuts, then remove the water bypass pipe.
b. Remove the gasket.
71. REMOVE CRANKSHAFT POSITION SENSOR
72. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Using a 24 mm deep socket wrench, remove the oil pressure switch.