Part 2
With A/T:
With M/T:
With A/T:
With M/T:
Except PZEV:
PARTIAL ENGINE ASSY
REPLACEMENT
41. REMOVE SPEED SENSOR FRONT RH (W/ ABS)
HINT: Use the same procedures described for the LH side.
42. DISCONNECT TIE ROD ASSY LH
a) Remove the cotter pin and castle nut.
b) Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011
NOTICE: Be careful not to damage the cover of the ball joint.
43. DISCONNECT TIE ROD ASSY RH HINT:
Use the same procedures described for the LH side.
44. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a) Remove the bolt and 2 nuts, as shown in the illustration.
b) Using a plastic hammer, disconnect the drive shaft from the axle hub.
45. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Use the same procedures described for the LH side.
46. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T)
a) Fix the crankshaft and remove the 6 setting bolts.
47. REMOVE STEERING INTERMEDIATE SHAFT ASSY
a) Loosen the sliding yoke bolt.
b) Place matchmarks on the intermediate shaft and control valve shaft.
c) Remove the bolt and the steering intermediate shaft.
d) To prevent the steering wheel from rotating, fix the wheel with the seat belt.
NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged.
48. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a) Set the engine lifter.
b) Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.
c) Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
d) Carefully remove the engine assembly from the vehicle.
e) Install the 2 engine hangers as shown in the illustration.
Parts No.
Torque: 38 Nm (387 kgf-cm, 28ft. lbs.)
Using a chain block and an engine sling device, hang the engine assembly.
49. REMOVE VANE PUMP ASSY
a) Disconnect the PS oil pressure switch connector.
b) Remove the 2 bolts and vane pump from the engine.
50. REMOVE FRONT FRAME ASSY
a) A/T: Remove the nut from the engine mounting insulator LH.
b) M/T: Remove the bolt from the engine mounting insulator LH.
c) Remove the nut from the engine mounting insulator RH.
d) Remove the bolt from the engine mounting insulator FR.
e) M/T: Remove the bolt from the engine lateral control rod.
f) Raise the engine assembly and separate the front frame.
51. REMOVE FRONT DRIVE SHAFT ASSY LH
52. REMOVE FRONT DRIVE SHAFT ASSY RH
53. REMOVE STARTER ASSY
54. SEPARATE AUTOMATIC TRANSAXLE ASSY (A/T)
55. SEPARATE MANUAL TRANSAXLE ASSY (M/T)
56. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (A/T)
a) Using SST, fix the crankshaft.
SST 09960-10010 (09962-01000, 09963-01000)
b) Remove the 8 bolts, rear spacer, drive plate and front spacer.
57. REMOVE CLUTCH COVER ASSY (M/T)
58. REMOVE CLUTCH DISC ASSY (M/T)
59. REMOVE FLYWHEEL SUB-ASSY (M/T)
a) Using SST, fix the crankshaft.
SST 09960-10010 (09962-01000, 09963-01000)
b) Remove the 8 bolts, rear spacer and flywheel.
60. INSTALL ENGINE STAND
61. REMOVE INTAKE MANIFOLD
a) Remove the 5 bolts, 2 nuts, intake manifold and gasket.
62. INSPECT INTAKE MANIFOLD
a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.20 mm (0.0079 inch)
If the warpage is greater than maximum, replace the manifold.
63. REMOVE VENTILATION HOSE
64. REMOVE VENTILATION HOSE NO.2
65. REMOVE ENGINE WIRE
66. REMOVE INTAKE MANIFOLD INSULATOR NO.1
67. REMOVE OIL LEVEL GAGE SUB-ASSY
68. REMOVE OIL LEVEL GAGE GUIDE
69. REMOVE MANIFOLD CONVERTER INSULATOR NO.1
70. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY
a) Remove the 3 bolts, 2 nuts, and the No. 1 and No. 2 exhaust manifold stays.
b) Remove the 5 nuts, exhaust manifold converter and gasket.
71. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY
a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.70 mm (0.0276 inch)
If the warpage is greater than the maximum, replace the manifold.
72. REMOVE WATER INLET
73. REMOVE THERMOSTAT
74. REMOVE IGNITION COIL ASSY
75. REMOVE V-RIBBED BELT TENSIONER ASSY
a) Remove the bolt, nut and belt tensioner.
76. REMOVE DRIVE SHAFT BEARING BRACKET
77. REMOVE ENGINE MOUNTING BRACKET RH
78. REMOVE FUEL DELIVERY PIPE W/INJECTOR
79. REMOVE WATER BY-PASS PIPE NO.1
80. REMOVE ENGINE OIL PRESSURE SWITCH ASSY