ENGINE ASSEMBLY REMOVAL

PLACE FRONT WHEELS FACING STRAIGHT AHEAD
WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

Click here
SEPARATE BATTERY NEGATIVE CABLE
REMOVE FRONT WHEELS
REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)
REMOVE ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)
REMOVE ENGINE SIDE UNDER COVER LH (w/ Engine Side Under Cover LH)
REMOVE ENGINE SIDE UNDER COVER RH (w/ Engine Side Under Cover RH)
DRAIN ENGINE COOLANT
CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Remove the radiator cap.
2. Loosen the radiator drain plug and a cylinder block drain plug. Then drain the coolant.
DRAIN ENGINE OIL
1. Remove the oil filler cap.
2. Remove the oil drain plug and drain the engine oil from the oil pan.
  
  Note
  
  Collect the oil in a disposable oil container.
3. Clean the oil pan drain plug and install it with a new gasket.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

Tech Tips

Use the same procedures described for the LH side. Click here
REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

Tech Tips

Use the same procedures described for the LH side. Click here
REMOVE FRONT DOOR SCUFF PLATE
REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Roll up the carpet, and remove the 5 bolts and engine service hole sub cover.
REMOVE FAN & GENERATOR V BELT
1. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the drive belt. Then remove the drive belt.
  
  Note
  
  When removing the drive belt, do not use the idle pulley's bolt.
  
  Tech Tips
  
  After removing the drive belt, move the tensioner upward to the maximum amount.
DISCONNECT RADIATOR HOSE INLET
1. Remove the clamp, and disconnect the radiator hose inlet from the engine.
DISCONNECT RADIATOR HOSE OUTLET
1. Remove the clamp, and disconnect the radiator hose outlet from the engine.
DISCONNECT HEATER WATER HOSE INLET A
1. Disconnect the heater water inlet hose A from the heater unit.
DISCONNECT HEATER WATER HOSE OUTLET B
1. Disconnect the heater water outlet hose B from the heater unit.
DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY
1. Disconnect the fuel vapor feed hose from the VSV.
DISCONNECT UNION TO CONNECTOR TUBE HOSE
1. Disconnect the union to connector tube hose from the intake manifold.
REMOVE AIR PRESSURE SENSOR (w/ Manifold Absolute Pressure Sensor)
1. Disconnect the connector.
2. Disconnect the vacuum hose and clamp.
3. Detach the wire harness clamp
4. Remove the 2 bolts and air pressure sensor together with the bracket.
5. Remove the bolt and air pressure sensor.
REMOVE INTAKE AIR CONNECTOR
1. Slide the clamp and disconnect the No. 2 ventilation hose and vacuum hose. (A)
2. Loosen the 2 hose clamp bolts. (B)
3. Remove the 2 bolts and intake air connector. (C)
DISCONNECT AIR HOSE NO.5 (w/ Secondary Air Injection System)
1. Disconnect the air hose No.5 from the air switching valve.
DISCONNECT FUEL HOSE
1. Pull the fuel hose connector cover up to release the lock. Click here
2. Disengage the fuel connector to disconnect the fuel hose. Click here
DISCONNECT FUEL HOSE NO.2
1. Remove the clamp, and disconnect the fuel hose No.2 from the delivery pipe.
DISCONNECT VANE PUMP ASSEMBLY
1. Disconnect the PS fluid pressure switch connector.
2. Remove the 2 bolts and disconnect the pump from the engine.
3. Support the vane pump securely.
REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
REMOVE OIL LEVEL GAUGE GUIDE
1. Remove the bolt and gauge guide.
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
1. Disconnect the compressor connector.
2. Remove the 4 bolts and disconnect the compressor from the engine.
  
  Tech Tips
  
  Disconnect the compressor with the low pressure hose and high pressure hose stuck by suspended from the rope.
3. Support the cooler compressor securely.
DISCONNECT ENGINE WIRE
1. Disconnect the wire harness support of the ECM.
2. Disconnect the connectors of the ECM.
3. Disconnect the clamps of the engine wire and earth cable.
4. Disconnect the +B terminal of the starter and connector from the generator.
5. Remove the nut and disconnect the cable from the engine room J/B.
REMOVE EXHAUST PIPE ASSEMBLY FRONT (for Super Long Wheelbase)
1. w/ Secondary air injection system:
  1. Disconnect the fuel ratio sensor connector.
  2. Remove the fuel ratio sensor. Click here
2. For unleaded gasoline engine:
  1. Disconnect the oxygen sensor connector.
  2. Remove the oxygen sensor. Click here
3. Remove the 4 bolts, 2 nuts, and 2 compression springs.
4. Remove the 2 gaskets from the exhaust pipe assembly front.
5. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front.
REMOVE EXHAUST PIPE ASSEMBLY FRONT (for Long Wheelbase)
1. w/ Secondary air infection system:
  1. Disconnect the fuel ratio sensor connector.
  2. Remove the fuel ratio sensor. Click here
2. For unleaded gasoline engine:
  1. Disconnect the oxygen sensor connector.
  2. Remove the oxygen sensor. Click here
3. Remove the 4 bolts, 2 nuts, and 2 compression springs.
4. Remove the 2 gaskets from the exhaust pipe assembly front.
5. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front.
REMOVE EXHAUST PIPE ASSEMBLY CENTER (for Super Long Wheelbase)
1. Remove the 2 bolts and gasket from the exhaust pipe assembly center.
2. Disconnect the exhaust pipe supports, and remove the exhaust pipe assembly center.
REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)
1. Put matchmarks on both flanges.
2. Remove the 4 nuts, bolts and washers.
  
  Tech Tips
  
  If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller with center bearing shaft assembly from the differential companion flange.
3. Remove the 2 bolts and center support bearing assembly No.1.
4. Remove the propeller with center bearing shaft assembly.
5. Insert SST in the transmission to prevent oil leakage.
  
  Note
  
  Do not damage the oil seal.
  1. Use the following SST for the automatic transmission.
    
    SST
    
    09325-40010
  2. Use the following SST for the manual transmission.
    
    SST
    
    09325-20010
REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)
1. Put matchmarks on both flanges.
2. Remove the 4 nuts, bolts and washers.
  
  Tech Tips
  
  If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.
3. Remove the propeller shaft assembly.
4. Insert SST in the transmission to prevent oil leakage.
  
  Note
  
  Do not damage the oil seal.
  1. Use the following SST for the automatic transmission
    
    SST
    
    09325-40010
  2. Use the following SST for the manual transmission
    
    SST
    
    09325-20010
REMOVE SPEED SENSOR FRONT LH (w/ ABS)
1. Remove the 2 bolts, and separate the speed sensor from the steering knuckle.
  Note
  
  Be careful not to damage the speed sensor.
  
  Prevent foreign matter from adhering to the speed sensor.
REMOVE SPEED SENSOR FRONT RH (w/ ABS)

Tech Tips

Use the same procedures described for the LH side.
REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY LH
1. Remove the 2 bolts, and disconnect the brake caliper assembly.
  
  Note
  
  Use a wire or an equivalent to keep the brake caliper from hanging down by the flexible hose.
REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY RH

Tech Tips

Use the same procedures described for the LH side.
SEPARATE FRONT SUSPENSION SUB-ASSEMBLY UPPER LH
1. Remove the cotter pin and loosen the nut.
  
  SST
  
  09628-62011
  
  Note
  
  Do not remove the nut.
2. Using SST, separate the steering knuckle from the suspension upper arm and remove the nut.
  Note
  - Fix the steering knuckle with a wire so that the flexible hose does not receive excessive force.
  - Do not damage the ball joint dust cover.
SEPARATE FRONT SUSPENSION SUB-ASSEMBLY UPPER RH

Tech Tips

Use the same procedures described for the LH side.
SEPARATE SHOCK ABSORBER ASSEMBLY FRONT LH
1. Remove the bolt and separate the front shock absorber from the front suspension lower arm.
SEPARATE SHOCK ABSORBER ASSEMBLY FRONT RH

Tech Tips

Use the same procedures described for the LH side.
SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)
1. Put matchmarks on the control cable assembly and the outer lever.
2. Remove the 2 nuts and separate the transmission control cable from the outer lever.
3. Using a screwdriver, disengage the claws of the 2 clips.
4. Remove the transmission control cable and 2 clips from the transmission control cable bracket No.1.
SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)
1. Remove the 2 bolts and separate the clutch release cylinder.
REMOVE TRANSMISSION OIL LEVEL GAUGE SUB-ASSEMBLY (for Automatic Transmission)
1. Remove the transmission oil level gage sub assembly from the transmission oil filler tube.
REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)
1. Remove the 2 bolts transmission oil filler tube sub-assembly.
2. Remove the O-ring from the oil filler tube sub-assembly.
DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transmission)
1. Remove the nut and disconnect the transmission control cable assembly from the transmission control shaft lever assembly.
2. Remove the clip and disconnect the transmission control cable assembly from the transmission control cable bracket.
DISCONNECT OIL COOLER HOSE (for Automatic Transmission)
1. Remove each clamp and disconnect the oil cooler inlet hose and oil cooler outlet hose from the oil cooler tube.
SEPARATE STEERING TORQUE SHAFT ASSEMBLY
1. Loosen bolt (A) and remove bolt (B), then slide the steering torque shaft assembly.
  Tech Tips
  
  Do not remove bolt (A).
  
  Do not disconnect the steering torque shaft assembly from the power steering link assembly.
2. Put matchmarks on the steering torque shaft assembly and the power steering link assembly.
3. Separate the steering torque shaft assembly from the power steering link assembly.
REMOVE ENGINE ASSEMBLY WITH TRANSMISSION
1. Using the engine lifter, hold the engine assembly and separate the rear engine mount.
2. Remove the stabilizer brackets and 16 bolts of the front suspension cross member.
3. Remove the engine assembly w/ transmission out of the vehicle slowly and carefully.
REMOVE STARTER ASSEMBLY (for 1.6 kW Type)
1. Remove the 2 bolts, then remove the ground cable and bracket.
2. Remove the nut and disconnect the wire harness from terminal 30.
3. Disconnect the terminal 50 connector from the starter assembly.
4. Remove the 2 bolts and the starter assembly.
REMOVE STARTER ASSEMBLY (for 1.7 kW Type)
1. Remove the 2 bolts, then disconnect the ground cable and wiring harness clamp bracket.
2. Open the terminal cap.
3. Disconnect the starter connector.
4. Remove the nut and disconnect the starter wire.
5. Remove the 2 bolts and starter assembly.
REMOVE STARTER ASSEMBLY (for 2.0 kW Type)
1. Remove the 2 bolts, then disconnect the ground cable and wiring harness clamp bracket.
2. Open the terminal cap.
3. Remove the nut, and then disconnect the starter wire harness.
4. Disconnect the starter connector.
5. Remove the 2 bolts and starter assembly.
REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

Click here
REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

Click here
REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)
1. Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.
2. Loosen each set bolt one turn at a time until spring tension is released.
3. Remove the set bolts, and pull off the clutch cover assembly.
  
  Note
  
  Do not drop the clutch disc assembly.
REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

Note

Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel sub-assembly away from oil and foreign matter.
REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
1. Fix the crankshaft with SST.
  
  SST
  
  09213-54015 ( 91651-60855 )
  
  09330-00021
2. Remove the 10 bolts and flywheel.
REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)
1. Fix the crankshaft with SST.
  
  SST
  
  09213-54015 ( 91651-60855 )
  
  09330-00021
2. Remove the 10 bolts, spacer RR, drive plate and spacer FR.
REMOVE REAR END PLATE
1. Remove the 2 bolts and rear end plate.
INSTALL ENGINE HANGERS
1. Install the engine hangers with the bolts.
  
  Torque:
  
  42 N*m { 428 kgf*cm, 30 ft.*lbf }
  
  Tech Tips
  
  Engine Hangers 12281-75040
  
  Bolt 91552-A1020
  
  Note
  
  Use new bolts for the engine hangers.
REMOVE FRONT SUSPENSION CROSS MEMBER SUB-ASSEMBLY
1. Hold the engine with the engine sling device and chain block.
2. Remove the 4 bolts from the engine mounting insulator.
3. Remove the engine assembly by operating the engine sling device and chain block.
INSTALL ENGINE STAND
REMOVE ENGINE WIRE
1. Remove the engine wire from the engine assembly.
REMOVE VENTILATION PIPE
1. Remove the bolt and ventilation pipe.
REMOVE THROTTLE BODY ASSEMBLY
1. Disconnect the throttle motor connector. (A)
2. Slide the clamp and disconnect the water by-pass hose. (B)
3. Slide the clamp and disconnect the No. 2 water by-pass hose. (C)
4. for Type A:
  
  Remove the 2 bolts and 2 nuts, and then remove the throttle body assembly. (D)
5. for Type B:
  
  Remove the 4 bolts and throttle body assembly. (D)
6. Remove the gasket from the intake manifold.
REMOVE INTAKE MANIFOLD
1. Disconnect the ventilation hose No.3.
2. Remove the 5 bolts, 2 nuts, intake manifold and gasket.
REMOVE IGNITION COIL ASSEMBLY
1. Remove the bolts and ignition coil assembly.
REMOVE SPARK PLUG
REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
Note

Be careful not to drop the injectors when removing the delivery pipe.
1. Disconnect the fuel hoses.
2. Disconnect the 4 injector connectors.
3. Remove the 2 bolts O-ring and fuel pulsation damper assembly.
4. Remove the 2 bolts and delivery pipe together with the 4 injectors.
5. Remove the delivery pipe spacers.
6. Using a screwdriver, pry out the 4 spacers from the cylinder head.
REMOVE INJECTOR ASSEMBLY
1. Pull out the 4 injectors from the delivery pipe.
2. Remove the O-rings from the injectors.
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
1. Remove the 4 bolts and the heat insulator No.1.
REMOVE INTAKE PIPE NO.4 (w/ Secondary Air Injection System)
1. Remove the 4 nuts and intake pipe No.4.
2. Remove the 2 gaskets.
REMOVE AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection Ststem)
1. w/ Manifold Absolute Pressure Sensor:
  
  Disconnect the vacuum hose from the air switching valve assembly.
2. Disconnect the connector.
3. Remove the 2 nuts and the switching valve.
REMOVE EXHAUST MANIFOLD
1. w/o Secondary air injection system:
  1. Remove the 6 nuts, exhaust manifold and gasket.
2. w/ Secondary air injection system:
  1. Remove the 8 nuts, exhaust manifold and gasket.
REMOVE FAN PULLEY
1. Remove the 4 nuts, fan pulley and fan spacer.
REMOVE WATER BY-PASS PIPE NO.1
1. Remove the bolt, 2 nuts, water by-pass pipe and gasket.
REMOVE WATER INLET
1. Remove the 2 nuts, bolt, water inlet and gasket.
REMOVE THERMOSTAT
1. Remove the thermostat.
REMOVE GENERATOR ASSEMBLY
1. Disconnect the generator connector.
2. Remove the terminal cap.
3. Remove the nut and disconnect the wire harness from terminal B.
4. Remove the 3 bolts and generator assembly.
REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (w/ Air Conditioning System)
1. Remove the 5 bolts and compressor mounting bracket.
REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
1. Remove the bolt, pulley plate, collar, and idler pulley sub-assembly No.1.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
1. Remove the 2 bolts and belt tensioner.
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Using a 24 mm deep socket wrench, remove the oil pressure switch.
REMOVE KNOCK CONTROL SENSOR
1. Disconnect the knock control sensor connector.
2. Remove the bolt and the knock control sensor.
REMOVE WATER TEMPERATURE SENSOR
1. Using a 19 mm deep socket wrench, remove the water temperature sensor.
REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
1. Remove the 4 bolts and mounting bracket.
REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
1. Remove the 4 bolts and mounting bracket.
REMOVE ENGINE OIL LEVEL SENSOR
1. Remove the 4 bolts and engine oil level sensor.