Part 2

With A/T:

With M/T:

With A/T:

With M/T:

Except PZEV:

PARTIAL ENGINE ASSY
REPLACEMENT
41. DISCONNECT TIE ROD ASSY LH

a) Remove the cotter pin and nut.
b) Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011

NOTICE: Do not damage the dust cover of the ball joint.

42. DISCONNECT TIE ROD ASSY RH

HINT: Use the same procedures described for the LH side.

43. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH

a) Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
b) Using a plastic hammer, disconnect the drive shaft from the axle hub.
44. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH

HINT: Use the same procedures described for the LH side.

45. REMOVE STARTER ASSY
46. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
47. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT

a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b) Remove the 2 bolts and flywheel housing under cover.

c) Remove the 6 torque converter setting bolts.
48. DISCONNECT STEERING INTERMEDIATE SHAFT ASSY

a) Loosen the sliding yoke bolt.

b) Place matchmarks on the steering intermediate shaft and control valve shaft.
c) Remove the bolt and disconnect 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.

49. REMOVE GENERATOR ASSY
50. REMOVE GENERATOR BRACKET NO. 2
51. REMOVE GENERATOR BELT ADJUSTING BAR

a) Remove the 2 bolts, 2 nuts and the adjusting bar.
52. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH

a) Remove the bolt, nut and adjusting bar bracket.
b) Remove the 3 bolts and disconnect the compressor.

HINT: Hang up the hoses instead of detaching them.

53. 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 engine hanger as shown in the illustration.
No. 2 engine hanger: Part No.12282-20020
Bolt: Part No.91621-60822
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
f) Using a chain block and an engine sling device, hang the engine assembly.
54. REMOVE VANE PUMP ASSY

a) Remove the power steering oil pressure sensor harness.
b) Remove the pressure feed tube clamp.
c) Remove the 2 bolts and vane pump.
55. REMOVE FRONT FRAME ASSY

a) Remove the 2 nuts and disconnect the engine mounting insulator RH and LH.

b) Remove the bolt and disconnect the engine mounting insulator FR.
56. REMOVE FRONT DRIVE SHAFT ASSY LH
57. REMOVE FRONT DRIVE SHAFT ASSY RH
58. REMOVE ENGINE WIRE
59. REMOVE AUTOMATIC TRANSAXLE ASSY
60. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
61. INSTALL ENGINE STAND
62. REMOVE INTAKE AIR SURGE TANK

a) Disconnect the throttle body connector.
b) Disconnect the water by-pass hose No. 3.
c) Disconnect the water by-pass hose No. 2.
d) Disconnect the union to check valve hose.

e) Disconnect the ventilation hose.

f) Remove the 3 nuts and separate the pressure feed tube.

g) Remove the 2 bolts and engine hunger No. 1.
h) Remove the 2 bolts and surge tank stay No. 1.
i) Remove the 2 bolts and surge tank stay No. 2.

j) Using an 8 mm socket hexagon wrench, remove the 4 bolts.
k) Remove the 2 nuts, emission control valve bracket and surge tank.
l) Remove the gasket from the surge tank.
63. INSPECT INTAKE AIR SURGE TANK

a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.10 mm (0.0039 inch)
If the warpage is greater than the maximum, replace the manifold.
64. REMOVE IGNITION COIL ASSY
65. REMOVE INTAKE MANIFOLD

a) Remove the nut and disconnect the ground cable.
b) Disconnect the 6 fuel injector connectors.

c) Uniformly, loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.
66. INSPECT INTAKE MANIFOLD

a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake surge tank for warpage.

Maximum warpage

If warpage is greater than the maximum, replace the manifold.
67. REMOVE WATER OUTLET
68. REMOVE EXHAUST MANIFOLD SUB-ASSY RH

a) Disconnect the A/F sensor connector.
b) Remove the 3 bolts and insulator.

c) Uniformly loosen and remove the 6 nuts in the sequence shown in the illustration.
d) Remove the manifold and gasket.
69. INSPECT EXHAUST MANIFOLD SUB-ASSY RH

a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 inch)
If the warpage is greater than the maximum, replace the manifold.
70. REMOVE MANIFOLD STAY NO.2

a) Remove the 2 bolts and manifold stay.
71. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2

a) Remove the 2 bolts and insulator.

b) Remove the bolt, nut and insulator.
72. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2

a) Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration.
b) Remove the converter and gasket.
73. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2

a) Remove the 3 bolts and pump bracket.
76. REMOVE GENERATOR BRACKET NO.1
77. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
78. REMOVE WATER INLET PIPE
79. REMOVE WATER INLET
80. REMOVE THERMOSTAT